REVOLVING FIELD GENERATORS REVOLVING GENERAL . SECTION 4. INDEX FIELD GENERATORS ....« MAGNECITER . 6-0-0 ee eee eee eee ‘Troubleshooting Testing « Automatic Field Flashing Installing New Rectifiers Exciter Voltage Test... sete ees MAINTENANCE AND ADJUSTMENTS J-Series (Specs A Through Z) «+ + + + Brosbes ose e eee cece cen e ee 6 Rene see eee 6 Troubleshooting » . ++. « eee No-Voltage Buildup ss. see eee Over-Voltage or Fluctuating Voltage . . - Generator Beating... . - Collector Rings... +. + « Magneciter Alternator Testing Rotor Continuity Stator Continuity 66 eee ee eee eee Battery Charging Windings GENERATOR DISASSEMBLY... .. . - GENERATOR ASSEMBLY TABLE 4-1. TABLE 4 TABLE 4-4, . EXCITER VOLTAGE VALUES... . « |. MAGNECITER DIAGRAMS . . MAGNECITER TROUBLESHOOTING VOLTAGE VALUES (Generator Running) EXCITER RESISTANCE VALUES . 44 44 44 44 43 44 42 47 47 4-7 47 4.16 416 416 47 447 47 417 4a7 418 418 418 418 4-19 43 44 48 48 410 4a 412 44 415REVOLVING FIELD GENERATORS GENERAL Keeping in mind the material on revolving armature power generation in the preceding section we can now discuss revolving field generators. Suppose instead of turning a coil of wite in the magnetic field rotated inside the coil, The result is a revolving field generator (Figure 4-1). The revolving field is the olor and permanently fixed winding is the stator. With this type of generator there is no need for slip rings to transfer power from the stationary armature coils. Slip rings are used to supply direct current to the electromagnetic field of the alternator. Onan gener ators use a static exciter, a non rotating device that converts AC output to DC and regulates current to the field. This static exciter is called a Magneciter igure 4-2). ‘The output frequency of the revolving field generator depends directly on its rotating speed. The voltage output of this generator is determined by rotating speed, number of turns in the stator, and the field strength by controlling the field current, The magne- citer allows the adjusting of output voltage over a Limited range — 3% at a steady speed — and has rapid recovery capabilities from @ sudden load application, or removal. MAGNECITER DESCRIPTION, TROUBLESHOOTING, AND REPAIR. ‘The static exciter (Magneciter) supplies direct current to the alternator field coils and regulates the voltage produced by the alternator. Voltage stabilization cecurs within two seconds after a change in load. Voltage regulation should be within +3 percent. ‘The Onan static exciter has no moving parts and con- sequently demands minimum maintenance. By period- ically performing preventive maintenance (blowing dust from the unit using filtered, low pressure ait), corrective maintenance will be virtually eliminated. Corrective maintenance can be handled by anyone with 8 knowledge of basic electricity and with the proper equipment for applying that knowledge. Most trouble shooting can be accomplished with a multimeter ot a battery operated volt-ohmmeter, and a 120-volt, 25- watt AC test lamp. Troubleshooting Troubles are Listed in advancing order, from no output voltage to a rated but fluctuating output voltage. The relationship between trouble and cause is not always consistent from model to model, so the following in- formation must be used as a guide, not an absolute rule! The column entitled “Method” indicates the method for testing a standard component. When the word “None” appears in that column, all the informa tion needed to complete the check'is given in the column headed “Corrective Action”. When more than one letter appears in thet column for a single action, GENERATOR BLOWER, i Kes: ROUSING: aie stator wINOINes, MAGNECITER ASetaLy MAGHECITER ‘coven A co eeu FIGURE #1. REVOLVING FIELD GENERATORENGINE. ‘GENERATOR fee STATIC EXCITER REGULATOR __ ——— NS Hag, af ey f Ee pre ; ‘gvbaseteD RECTIFIERS, a XFS Rien 3 i ieee F pen “AY if Hh Bs TT aA recriFiers. FIGURE 42. ONAN MAGNECITER mote than one method of checking a component ot situation is given in the section on testing. NOTE: I¢ is imporative that the testing procedures are completely understood by the service technician before attempting to perform corrective procedures. TESTING [RRS] Avoid ero the ot tad of tester (Figure 4-3) when checking @ Magneciter component installed on a generator. A {ester with an isolation transformer circuit (Figure 4-4) is not subject to such a problem. This is the preferred type to use with a Magneciter. Because more than one method of testing Magneciter components can be used, test procedures for both multimeters and continuity testers are outlined here. METHOD A Rectifier: Using an chmmeter (multimeter) L. Select the middle resistance range (RX10 or RX100) for measurements. 2. Isolate the rectifier by disconnecting one end from its point of connection 3. Connect the test leads to the rectifier ends and observe the meter reading. 4. Reverse the leads and again observe the meter reading. Results: a. RECTIFIER IS GOOD if one reading is much higher than the other. b. RECTIFIER IS DEFECTIVE if both readings are low, indicating the presence of a shott, or if both readings ate high, indicating the pres- fence of an open circuit. In either case, the rectifier should be replaced. Rectifier: Using 6-volt buzzer tester 1. Connect tester leads to rectifier ends. 2, Reverse the leads and connect again. Results: 8, RECTIFIER IS GOOD if there is @ buzz for one connection and no buzz for the other.TABLE 1. MAGNECITER TROUBLESHOOTING NATURE OF TROUBLE PROBABLE CAUSE CORRECTIVE ACTION METHOD Generator will not build up Circuit breaker in “off"” or Reset and close breaker None voltage “teipped’” position Open in circuit bresker Stop plant and check None breaker continuity No AC power to Magneciter | Check AC voltage at E1-E2 } None with the plant operating*, Voltage should be 5 percent of the rated voltage. If not, check continuity from E1-E2 back to the generator 1 Shorted or Grounded Replace Rotor Ohmmeter Rotor ‘or Series Test Light Contacts dirty in Build-up Stop plant. Clean by None Relay of 02SXINIA drawing hard surfaced paper between contacts Partial loss of residual With plant operating *, Jork in Rotor short out reactor(s) Field Rectifiers W & Z Test rectifiers and replace AorB or X & ¥ open if defective Field Rectifiers X & Y Test rectifiers and replace Aor B shorted if defective Output vottage slow to er Field Rectifier ‘Test rectifiers and replace AoB build up. Circuit breaker X or ¥ shorted if defective ‘opens in about five seconds Output voltage slow to Either Field Rectifier Test rectifier and replace AaB build up. 5 percent below W ot Z shorted if defective rated voltage. Poor voltage regulation Output voltage slow to Open citcuit in one ot Test rectifier and replace Aor B build up and higher than more Control Rectifier if defective. Check rated voltage after build up soldered connections to rectifiers Output voltage slow to Open in one Field ‘Test rectifiers and replace Dok build up end 10 to 20 per- Rectifier if defective cent above rated voltage after build up Open circuit in Gate If Field Rectifiers ¥ and Z Dok winding G1-G2 of Reactor A or B check okay, check contin- uities of Gate windings G1-c2 * (WARNING ) USE CAUTION WEN TROUBLESHOOTING 4 UNIT IN OPERATION! ELECTRICAL SHOCK HAZARD IS PRESENT.TABLE 1. MAGNECITER TROUBLESHOOTING (Continued) NATURE OF TROUBLE PROBABLE CAUSE CORRECTIVE ACTION METHOD. Output voltage builds up Shorted winding in Control Test Control Reactor and F normally but less than rated Reactor replace if defective voltage after build up Output voltage builds up Compound winding $1-S2 Check wiring diagram for None normally with slightly less installed backward ot has polarity of Compound than rated voltage at no load open circuit windings thru Reactors and low voltage at full load ‘A and B and test for continuity Output voltage builds up Compound winding $1-S2 Check wiring diagram for None normally but 20 percent installed backward thru polarity of Compound above rated voltage after fone Reactor (A ot B) winding thru Reactor build up. Voltage regula- AaB tion poor. Output voltage builds up Open circuit in Control Check continuity from c normally but is 25 percent Rectifier bridge the junction of Control above rated voltage after Rectifiers Y and Z to build up the junction of Control Rectifiers W and X Output voltage builds up Shorted turn in gate Test Reactors A and B Dork normally but 125 to 150 winding G1-G2 of for shorted turns and percent above rated Reactor A ot B replace if defective voltage after build up Output voltage builds up Control winding C1-C2 ‘Check circuit connec- None normally but 150 to 200 of Reactor A or B tions of both Reactors percent shove rated polarized incorrectly A and B voltage after build up. No regulation possible Shorted turn in Control Test Reactors A and B DoE winding C1-C2 of for shorted turn and re- Reactor A or B place if defective Relay inoperative Check coil continuity; H replace if defective Open in Control Circuit Check continuity from None E1 to E2 thru Control Cireuit Generator voltage fluc- Incorrect setting on the Check resistance and G tuating while engine Stabilizing Resistor ‘compare with resistance running at constant speed value in Table Output Voltage High Shorted Control Diode Replace Diode c ca120 V.A.C. Supply 25Watt bulb FIGURE 43, TEST LAMP SET “Z-Short occurs if this lead is connected to grounded component 120 V.A.C. Supply 25 Walt bulb Transformer with separate primary and secondary windings Test leads are 1so- lofed from ground by transformer, FIGURE 44. RECOMMENDED TEST LAMP SET b, RECTIFIER IS DEFECTIVE if (1) there is no buzz for either connection or (2) @ buzz in both connections. In either case, replace the rectifier. METHOD B Using 120-volt AC tester 1. Make certain that no component patt of the Magne- citer is electrically grounded, 2. Isolate the rectifier by disconnecting one end from its point of connection. 3. Connect the two test leads together and observe the brilliance of the bulb, (Only the lead resis- tance is present in the test circuit.) 4, Connect the test leads to the rectifier and observe the brilliance of the bulb. Rectitier: Results: a. RECTIFIER IS GOOD if the bulb lights with a low intensity. b. RECTIFIER IS DEFECTIVE if the bulb lights with high intensity, indicating the presence of a short, or if the bulb fails to Light at all, indicating the presence of an open circuit. In either case, the rectifier should be replaced. BE SURE TO INSTALL THE RECTIFIER IN THE PROPER DIRECTION. (SEE WIRING DIAGRAM FOR CORRECT POLARITY.) NOTE: Results which are questionable can he affirmed by testing @ good rectifier. METHOD C Control Rectifier Bridge Circuit 1. Follow the sbove procedures for troubleshooting, rectifiers, The multimeter will indicate no con- tinuity in one direction or the other if an open circuit exists in the bridge circuit. METHOD D Reactors: Using an ohmmeter (multimeter) ‘These reactors are basically transformers having isolated primary and secondary windings. The reactors, can be tested as transformers. 1. Select the resistance range on the meter to the resistance specified in Table 3 for a given recti- fier model. 2. Isolate one gate winding by disconnecting either end of gate winding G1-G2 from its point of connection; for example, disconnect Gt at E2. 3. Measure the resistance in the gate winding across G1-c2. 4. Isolate the control winding by disconnecting either lead C1 or C2 from the terminal strip. Measure the resistance in the control winding, across C1-C2, 5. Conneet one meter lead to the disconnected gate winding lead and the other meter lead to the disconnected control winding lead and check for continuity. Results: @. REACTOR IS GOOD if resistance is within £20 percent of the value listed in Table 3 and if there is also no continuity between the control and gate windings. b, REACTOR IS DEFECTIVE if there is an open circuit in either the gate or the control wind~ ings. Continuity between the gate and the control windings is also en indication of a defective reactor. In either case, the reactor should be replaced, METHOD E Reactors A and B: Using 120-volt AC tester 1, Remove exciter from generator. 2. Make certain that no part of the Magneciter isgrounded. 3, Isolate the gate winding by disconnecting one lead from its point of connection. 4, Isolate the control winding by disconnecting both leads C1 and C2 from their points of connection. 5. Connect one test lead to G1 and the other test lead to G2 and observe the Jight bulb, 6. With the test leads still connected to the gate winding leads, short across leads C1 and C2 and again observe the bulb, 7. Connect one test lead to the control winding ead and the other test lead to one of the gate winding leads and observe the bulb, Results: REACTOR IS GOOD if bulb is dark for steps 5 and 7 but bright for step 6. b. REACTOR IS DEFECTIVE if bulb lights with low intensity for step 5, indicating the pres- ence of a short in either the gate winding ot the control winding. If the bulb lights for step 7, the gate winding and the control ate shorted together. If the bulb fails to light in step 6, there is very likely an open circuit in either the gate winding or the control wind- ing. Replacement is required. METHOD F Control Reactor: Using an ohmmeter only This method of testing the control reactor is not always positive, but the meter reading will indicate a trouble if one exists. 1, Isolste the control reactor by disconnecting common lead ““C” from its point of connection and carefully measure the resistance from this lead to the numbered lead on the control reactor. Results: 8. CONTROL REACTOR IS GOOD if resistance is within 10 percent of the value specified in Table 1. b. CONTROL REACTOR IS DEFECTIVE if no resistance is indicated between the common Jead “C” and the numbered lead. (Open circuit is indicated.) METHOD G Resistor: Using an ohmmeter only 1, The resistance should be measured with an obm- meter. See Table 3 for selecting the resistance range (RX10, RX100, etc.) so readings are near center of meter scale. 2. Isolate the resistor by disconnecting one end from its point of connection before measuring the resistance. Results: 2. RESISTOR IS GOOD if the measured resistance 466 falls within + 20 percent either way of the value given in Table 3. b. RESISTOR IS DEFECTIVE if there is no indication of continuity through the resistor for if the measured resistance exceeds the allowable tolerance NOTE: The stabilizing resistor can be ad- justed to bring the specified resistance within the required limits. METHOD H Build-up Relay Coil: Using an ohmmeter ‘This test will determine whether the resistance through the coil winding is within tolerance. 1. Isolate the coil by disconnecting one of its leads. With the meter adjusted to indicate center scale resistance reading, connect the meter leads to the coil. Results: 2. COIL IS GOOD if 525 chms + 10 percent resis- tance is measured. b. COIL IS DEFECTIVE if no resistance or low resistance is indicated; replace the reley. METHOD J Producing Voltage Build-up: ‘The first method used is shorting out the gate te~ actor(s) (temporarily removing their resistance) and thus applying full residual voltage to alternator field, Refer to diagrams to locate terminal points for the jumper connections. Have set running but be cautious! 1. For 04SX and O6SX press residual reset switch in Magneciter. EXCEPTION: For Spec A, which has no switch, place a jumper joining G1 - G2 - E2. Remove jumper wires when AC voltage starts to build up. 2. For 07SX, 1028X, and 2SX, jumper E2 to heat sink of rectifier No. 1. Remove jumper wires when AC voltage starts to build up. METHOD K Restoring Residual Magnetism (Pigue 4-5) If output voltage won't build up after trying Method J, then it may be necessary to restore residual magnetism by flashing the field with @ separate battery. Connect fa voltmeter across terminals El and E2. After starting the set touch the positive leads of a 6-volt dry cell, lantern battery to Fl positive (+) and the negative (-) ead to F2, When voltage starts to build-up, remove the battery leads. If voltage does not bulld up to normal and then drops to zero when you remove the battery leads, the trouble is a faulty component(s) in the exeiter. Flashing the fieldNOTE: You may substitute a 12-volt automotive battery for the 6-volt lantern battery if a 10-ohm resistance is connected in series with the battery to limit curcent to the exciter circuit, AUTOMATIC FIELD FLASHING (Figure 4-5) Some new units have an automatic field flashing circuit Which uses the set battery to “flash the field” when the engine cranks. This helps insure voltage buildup. All generators use this circuit except the SDR and 4XR models. The circuit is identified by the additional field rectifier (“'V") shown on the set exciter wiring dia- gram. ‘Two things are necessary for this circuit to work properly: 1, The plant battery must be negative ground. 2. Alternator lead T2 must be grounded (T2 must be grounded on a 3-phase, 4 wire.) If these conditions are not follow- ed, the field flashing circuit will be ineffective or it may damage the exciter. INSTALLING NEW RECTIFIERS (Figure 46). Observe caution when installing a new field rectifier, Applying too much torque on the holding aut will strain the internal connection and cause premature failure. ‘Small rectifiers used on the J series should not be tor= qued over 20-inch Ibs. If no torque wrench is available this is fingertight plus one-quarter turn. Larger rectifiers require 35 to 40-inch Ibs. of torque: EXCITER VOLTAGE TEST (Figure 4-7). A. Bench Test (Auxiliary Power) 1. Connect Variac to exciter terminals E1 and E2 as shown in Figure 5. 2. Connect an AC voltmeter to these same termi- nals Fi and E2, 3, Connect DC voltmeter to field leads F1 and F2. 4. Connect a 100 watt light bulb across these same terminals F1 and F: 5. Adjust Variac until voltage reaches value shown ia column 2 (according to exciter model shown on Onan nameplate). DC voltage should now be within limits shown in column 3, (TA BLE 4-2), B. Generator Running at No Load 1, Connect an AC voltmeter to exciter terminals El and E2 as shown in Figure 4-8. 2. Connect DC voltmeter to exciter terminals F1 and F2. 3, With generator running st recommended rpm and no load connected, AC voltage values should be the same as those given in column 1; DC voltage values should be the same as those shown in column 2 (according to exciter model). SEE TABLE 4-3, MAINTENANCE AND ADJUSTMENTS JsSeries Revolving field generators normally need little care other than periodic inspection of the exciter, ball- bearing, collector rings, and brushes. These’ items must be inspected at least every 1000 hours, NOTE: J-serios generator sets using 028K exciters require voltage build-up relay cleaning every 500 hours, Brushes (J-Series) To examine the brushes, brush springs, and slip rings the exciter cover at the rear of the generator must be removed. The exciter mounts on a hinged plate. Remove the sctew from the right side of the plate and swing the assembly outward, To remove the brush holders unscrew the four machine screws on the end- bell near the ballbearing (Figure 4-9). Fi) VOLTMETER wear (‘sink HOLDING NUT (00 NOT OVER TORQUE) FIGURE 45, FLASHING THE FIELD 4a7 FIGURE 46. INSTALLING NEW RECTIFIERSvaRIaC acin 3 100 WATT Lio he re 7. i, Qc VOLTMETER | Q AC VOLTMETER fo EI ho 2 | EXCITER TERMINAL, BlocK AC VOLTMETER — EXCITER TERMINAL BLOCK BC VOLTMETER FIGURE 4-7. BENCH TEST SCHEMATIC FIGURE 4-8. TEST SCHEMATIC (GENERATOR RUNNING AT NO LOAD) TABLE 4-2. VOLTAGE VALUES FOR BENCH TEST 1 2 3 Exciter | nominat | ac vouts | oc vouTs Move. | exciter | AT FIRE | AT FIRE voutace | pown* | pow O4SKIN 20 138-140 60-80 6SxIN 6SxiN 120 iaz129 60-80 06Sx51N 20 146-150 70-90 O7SxIN 120 Het19 60-80 O7SxSIN 120 136-140 70-90 1o2sxIN 120 Hiaeti9 70-90 102SX5IN 120 133-140 180-100 2SKIN 20 236-240 150-170 208 206-210 130-150 2SxSIN 240 250-262 150-170 208 22228 130-150 NOTE: All bench tast values are the same for 50 cycle ‘and 60 cycle models. + Value will vary with rheostat sexing TABLE 4-3. VOLTAGE VALUES FOR EXCITER (GENERATOR RUNNING AT NO LOAD) lexciter|nommat| 1 2 3 MODEL |excITER|Ac VOLTAGE|DC VoL TAGE|ENGINE| vouracd ATE!.e2 | ATFI,F2 |sPeED loasxin } 120 a4 2 1860) foosxin | 120 16 2 1860 lorsxin | 120 23 21 860 o2sxin | 120 im 19 860 asxin | 240 253 39 i875, 208 215 36 860 NOTE: Values will vary with engine speed and sheostar setting. All values atno load. 4-8TABLE 4-4. RESISTANCE VALUES Always use an accurate ohmmotet for checking resistance values. Resistance readings in the range of values found between G1 and G2 cannot be read with accuracy on the smuitimeter, MODEL OF CONTROL REACTOR LARGE REACTOR STABILIZING MAGNECITER [— a ae = a i RESISTOR SETTINGS cto2 | cto31 | Cto4 | Cto1 |crtoc2 | GitoG2 O2SXINIA 14.0 5.0 1.0 Fixed O7SXINIA, 23.0 9.0 15 113.0 O7SXINIB 23.0 9.0 7 113.0 O7SXINIC 18.0 9.0 75 150.0 102SX1NIA 23.0 85 30 80.0 102SX1NIB 18.0 85 30 80.0 2SX2N1A_ 155.0 175 a7 Fixed 2SX2NIB 150.0 178 37 Fixed O7SXS1NIA, 28.0 9.0 90 113.0 O7SXSINIB 28.0 9.0 90 113.0 O7SXSINIC. 22.0 9.0 90 150.0 1o2sxsinia | 28.0 as 38 80.0 102SX51NIB. 22.0 85 Ed 80.0 2SXS2NIA 192.0 45 Fixed 2SX52N1B, 180.0 48 Fixed O4SXINIA 125 11.0 177 Fixed O4SXINIB, 28, 3B, 4B 12.5 11.0 177 Fixed O6SKINIA 25 55 65 Fixed O6SXINIB, 2B, 3B, 4B 12.5, 55 66 Fixed O6SXSINIA| 15.0 6.6 79 Fixed O6SXSINIB, 2B, 3B, 4B 15.0 66 79 Fixed 4=9TABLE 4-5. 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WINDING REACTOR ‘B” conrnon WINDING REACTOR ‘A ‘COMPOUND WINDING. Ug TURN) CONTROL REACTOR COMPOUND WINDING Oa runn) frotaniry t-cATE: WINDING RECTIFIER ASSEMBLY There WINDING ‘O2SKINIA WAGNECITER 415BRUSH HOLDER | MOUNTING SCREWS INSTALL BRUSHES. Wit BEVELED Top SLANTING DOWN ‘TOWARD SPRING HOLDER “y To Remove arush ¢f SPRING PRESS ay SPRING HOLDER DOWN AND OUF AS Shon IN BROKEN tines. FIGURE 49, BRUSH LOCATION AND REPLACEMENT Brushes should be replaced when they wear to about 5/16 inch. Use only Onan parts when replacing Brushes. Other replacement brushes ‘may look identical but they may have entirely different electtical characteristics. TESTING AND REPAIR If repair work is necessary on the generator, it should be performed by a competent electrician who is familiar with operation of electric generating equipment. ‘TROUBLESHOOTING In the event of abnormal generator output voltage, observe the following procedures. 4a16 No Voltage Buildup: Remove the exciter cover and with the set running, operate the residual reset button on the Magneciter. NOTE: Early O4SX and O6SX models had no reset button. On these models place jumpers momentarily from GI to G2 of each reactor simultanoously with the unit running. On the 02SX exciter, the buildup relay automatically performs this function. Units beginning Spec P have a voltage tap at terminal 35 which allows automatic field flashing during unit cranking to assure voltage buildup. If output voltage won’t buildup after pushing the reset Dutton, flash the field (Figure 4-11). Connect @ volt= meter across the AC output, Then run the unit andmomentarily touch the leads of a 6-volt lantern battery to the exciter to brush leads . . . positive (+) to FI and negative (-) to F2, While viewing the voltmeter: 1. If voltage builds up to normal, trouble was due to lost residual in the field. 2. If voltage is low, the Magneciter is probably defective. (See Magneciter Troubleshooting Chart.) 3. If there is no voltage output with battery con- nected to Fl and F2, trouble is in alternator. Over-Voltage or Fluctuating Voltage: If the engine is operating at the correct speed, see Magneciter Trouble shooting Chart GENERATOR BEARING ‘The generator ballbearing is prelubricated and double- sealed. Inspect every 1000 hours with the unit running. If the set is used for “standby power”, replace bearing every five years, If used as “prime power", replace bearing every 10,000 hours or two years, Deterioration of the bearing grease due to oxidation makes this replacement necessar If the bearing becomes noisy, worn or otherwise de- fective, replace it, Remove the old ballbearing with 8 gear puller and press a new one into place (Figure 4-10), COLLECTOR RINGS The collector rings must be clean and free of burrs, scratches and marks. If necessary, use No. 00 sand- paper to clean the surface. Never use emery cloth of other conducting abrasives. Collector rings may have a dark brown or black appear ance. This is a thin lubricating film and aids the life of the brushes and slip rings. (Do not remove film.) If the collector rings ate grooved, out-of-round, pitted for rough so that good brush seating can’t be main tained, remove the rotor and refinish the rings in a athe,’ Remove or shield the ballbesring during re- finishing. The collector rings should have a Total Indicated Reading (T-LR.) of .002” MAGNECITER ‘The magneciter contains no moving parts except for the O2SX. Periodically blow out any dust and make certain thet all components and connections are For detailed magneciter description see the Magneciter, Description, Troubleshooting, and Repair portion of this section. ALTERNATOR TESTING Most alternator testing can be performed without disassembling the generator. ROTOR SHAFT FIGURE 410, BEARING INSTALLATION. TOUCH MOMENTARILY TO RESTORE RESIOUAL VOLT sou" ORY CELL BATTERY Fue VOLTMETER FIGURE 4-11 FLASHING THE FIELD, -17Test Rotor Continuity As Follows: Remove the brushes so none touch the collector rings. 1. Using an ohmmeter, test for grounding between each slip ring and the rotor shaft, 2. Test for a short or open circuit in rotor winding by measuring resistance of winding. It should measure between 3.5 and 4.8 ohms for the JB and between 2 and 3 ohms for the JC (at 70°F). If an accurate chmmeter isn’t available, check the rotor for open circuit ot grounding with an AC test lamp (Figure 4-12). Replace the rotor if it is grounded, of has an open citcuit or short. Test Stotor Continuity As Follows: 1. Disconnect the generator output leads in the control box. Use the wiring diagrams to determine the output leads in the control bos. "Use the wiring diagrams to determine the output lead coding. Using either the test lamp of an ohmmeter, check each winding of the stator for grounding to the laminations or frame. NOTE: Some generators have ground connections to the frame. Check the wiring diagrams. Using an accurate ohmmeter, test the resistance of each stator winding. Compare the resistances obtained. All windings of equal output voltage should indicate about the same resistance. An unusually low reading indicates a short; a high reading an open circuit. If the ohmmeter required for this test isn’t available, check for open cir cuits with the test Lamp. 3. If any windings are shorted, open-circuited ot grounded, replace the stator’ assembly. Before replacing the assembly, check the leads for broken wires or insulation and replace any defec- tive lead. If this does not correct the fault, replace the assembly. Only a competent rewinding, shop should attempt to rewind a defective stator. Bottery Charging Winding Tests: Remove the lead from from the battery polarity reconnection block to am- meter at the ammeter. Install a DC voltmeter between the lead and ground. At governed engine speed, the average DC output should be 19 to 21 volts. If the output is defective, test for open circuit or grounding in the leads and ‘windings. If leads are defective, replace them. If the winding is defective, replace the stator. GENERATOR DISASSEMBLY (Figure 4-14) 1. Disconnect the battery to prevent starting of the set. 2. Remove the exciter cover and open the exciter. This will reveal the rotor-thru-stud nut, 3. Remove the four machine screws on the end bell near the bearing and lift out the brush holders. 4, Remove the lead from the tapped adjustable resistor in the generator air outlet opening. 5. Remove the leads from the control box to the ignition system choke, start disconnect switch, etc. on the engine. 6. Remove generator-through-stud nuts, remove the end bell and stator assembly. Screwdriver slots in the adapter provide a means for prying the stator loose. Be careful not to let the stator touch or drag on the rotor. 7. Remove baffle ring from adapter. Turn rotor- through-stud aut to the end of the through stud, While pulling the rotor outward with one hand, strike @ sharp blow to the nut (in the direction of the through stud, not vertically) with a heavy, soft faced hammer to loosen the rotor from its tapered shaft fit. If the rotor does not come loose, strike it with a sharp downward blow in the center of the Jamination stack with @ lead or plastic hammer. Rotate the roter and repeat until it comes loose. Be careful not to hit the collector rings, bearings or windings. 8. After disassembly, all parts should be wiped clean and visually inspected. accidental TESTING FOR OPEN CIRCUIT wiscop avin snows eM TESTING FOR GROUNDS FIGURE 4-12, TESTING FOR OPEN CIRCUIT AND GROUNDS. 18GENERATOR ASSEMBLY . Clean and inspect all mating surfaces, Coat the mating area between the generator shaft and the engine crankshaft with 2 thin film of lubricating oil, “Molykote”” or equal. Install the rotor-through-stud in the engine crank- shaft Install the key in the crankshaft. Slide the rotor over the through-stud and onto the crankshaft. Be careful not to let the weight of the rotor rest on the through-stud, Install the baffle ring. Install generator through studs in the adapter. Install the stator and bearing support (end bell). Tighten the nuts on through-studs. NOTE: Make certain the B1 lead is placed through the grommet in the baffle ring and out the air discharge opening in the adapter. 10. u. 2. 1B. . Now torque down the rotorthrough-stud nut (55-60 ft. Ib.). Because the stator and bearing support were tightened before tightening the rotor, the rotor and stator ate automatically aligned. Tap the bearing support to the horizontal and vertical plane with 2 lead hammer to relieve stresses on the components (recheck torque). Reconnect the leads to the preheater, centrifugal switch and governor solenoid Install lead BL on the adjustable resistor. EROTORT Steck is oad to so tha it ie short and is kept away from the Blower. If necessary whon installing a new stator or leads, cut it shorter and reinstall the connector. Install the brushes and brush holders, |; Close the Magneciter, secure with four capscrews end install the end cover. HOIST AND SLING TO AVOID BENDING THROUGH TURN NUT OUT To ENO OF GENERATOR THROUGH STUD. STRIKE WITH SOFT HAMMER WHILE PRYING FIGURE 4-13, SUPPORTING THE ROTOR ADAPTER LOWER BAFFLE GENERATOR HiROUeN STUD coLLEcToR NG BROS END RELL. coutecror "RING BRUSH FIGURE 41 4-19 REVOLVING FIELD GENERATOR ASSEMBLY.