... ,.. ...

, ,
Generat ' ... Control ' Box
1 ' N BROS. PTY; LTD
"AAl f RFBT,
, ADELAiDE
' 43 TBLEPB Ni. fl
, "
I
,
I'
I

FOREWORD
Publication No. 1448 Ex. (Fifth Edition) 1963
This booklet is intended primarily for the small service station owner and mechanic
who. though not normally concerned with car" electrics." are nevertheless required
at some time or other to diagnose and correct electrical faults.
We believe that this booklet will serve to show you a way in which some of the more
common faults in the generator and regulator. on Lucas eqUipped cars and motor
. .
cycles. can be diagnosed and corrected-in many cases without having to remove the
units from the vehicle. Quick diagnosis is ensured if the tests are carried out in the
systematic manner outlined herefn.
Remember. always commence the tests at the source of supply-The Generator (Part 1.
Test 1).
PFj1063j L Printed in England
..
I N D E X OF
PART 1
Generator Tests for Models:
C39PV C42
C39Q C45PV-5
C40A C45PV-6
C4011 C45PVS-6
, C40AL C47
C40L C48
C40LQ
Pages 3 - 4
SYSTEMATIC
PART 2
Regulator Tests :
Compensated Voltage Con-
trol.
Lucas Models : MCR1, MCR2,
RF95, RF95j3, RF96, RF97,
RB106j1, RB106j2, RB107
and RB108
Pages 5 - 9
FAULT LOCATION
PART 3
Regulator Tests:
Current Voltage Control.
Lucas Model: RB310
3 Bobbin Type
with screw type electrical
adjustment
Pages 10 -16
Printed in England
No part of this book may be reproduced without permission.
JOSEPH LUCAS (EXPORT) LTD. 46 PARK STREET
' . ~
' . " ~ ' , t ' ~ "
PART 4
Regulator Tests:
Current Voltage Control.
Lucas Model: RB340
3 Bobbin Type
with cam type electrical
adjustment
Pages 17 - 26
LONDON W.1.
. .


The following tests should be carried out with a good quality Moving Coil Voltmeter. The meter should have a
of at least 20 volts, with divisions s.uitable for taking readings to within 05 of a volt. A meter of this standard
be SUitable for both 6 and 12-volt LUCAS eqUipped cars, trucks, etc., and 6 volt systems on motor . .-
ALWAYS CHECK BATTERY CONDITION BEFORE COMMENCING TESTS
PART 1
GENERATOR TESTS WITH THE MACHINE IN POSITION ON THE VEHICLE
Inspect generator mounting for t ightness of bolts, etc.
Inspect the fan belt for correct tension, adjust if necessary. If worn or frayed fit a new belt. Make sure drive
pulleys are correctly aligned.
Ifthe belt and generator mounting are satisfactory and pulleys correctly aligned then proceed r-O";Test 1.
VOLTMETER CONNECTION READING ACTION
TEST 1. A. 2-4 volts as generator is run up to Armature and brush connections O.K.
Disconnect leads from generator. charging speed (approx. 3,000 rev/ proceed to Test 2.
Connect one lead of voltmeter to D min) (6 and 12 volt systems).
terminal and the other to a good
ground. B. Zero volts. Examine brushes and make sure they
Start engine ' .and raise speed until are free In their boxes making good
generator iS Ij!lnning at approx. contact on the commutator. If still
(
3,000 rev/min. no reading fault is in armature,
When ve'hicle has a positive ground which has to be replaced.
system positive meter lead must be
grounded. C. Rising volts with rising speed. Internal short between D and F ter-
minals, examine field coils and rectify
r
as necessary or fit replacement.
page 3

VOLTMETER CONNECTION READING ACTION
-
TEST 2. A. Rising volts with rising speed-full Generator in order, proceed to Test 3.
Connect meter as in Test 1. scale reading at fast tick-over.
Link terminals D and F on generator.
2-4 volts as engine is revved Open circuit in field coils, rectify as Gradually speed-" up engine to fast B. up (6
. " t ick-over" speed. If an ammeter and 12 volt systems) . necessary or fit replacement.
is used to link D and F, reading
should not be more than* 2 amps, C. Zero volts. Grounded field coils or field connection,
when normal voltage of system is rectify as necessary or fit replace-
registered on voltmeter. ment.
*25 for C42 with 4t ohm field.
TEST 3. A. 2-4 volts (6 and 12 volt systems). D lead from generator to control box
Reconnect leads of generator. is in order. Proceed to Test 4.
Remove leads from D and F terminals
at the control box. B. Zero volts. Rewire D lead which is open-circuited,
Connect one side of voltmeter to end or earthed.
of D lead, the other to a good
ground, speed generator up to C. Rising volts with rising speed. Locate short between D and F cables.
approx. 3,000 rev/ min.
TEST 4. A. Rising volts with rising speed. Cables from generator to control box
Leave voltmeter connected as in Test 3. are in order. Proceed to Test 5 in
Join D and F wires together. part 2,3, or 4 whichever is applicable.
Gradually speed up engine to fast
"tick-over" speed. B. Zero volts. Earthed F lead.
I
C. 2-4 volts (6 and 12 volt systems). Open circuit in field lead between
generator and control box.
page 4
J
PART 2
.
MODEL LRT9 REGULATOR-SINGLE CONTACT 2 BOBBIN TYPE
(Used with RF9S, 96, RB106j1, MCR2, etc.)
COMPENSATED VOLTAGE CONTRO L TESTS WI TH UNIT IN POSITION
On no account must these tests be made with the battery in circuit.
To isolate the battery from the generator put a piece of dry card between the cut-out points. Remember the output
of the generator, that is the current in amps. flowing from the generator to the battery is dependent on the state of charge of
the battery. The generator will give a high output when the battery is in a low state of charge and a low output when the
battery is fully charged. Regulators must therefore always be set on open-circuit, a condition which is most easily obtained by
inserting the piece of dry card as described above, alternatively, withdraw cables from "A' and A1 terminals and join together
temporarily.
VOLTMETER CONNECTION READING ACTION
-
TEST 5. A. Battery voltage. Regulator ground connection in good
Reconnect generator leads to control order. Proceed to Test 6.
box terminals D and F.
Connect one lead of voltmeter to ter- B. Less than battery voltage, or zero Re.ctify bad ground or broken ground
minal A. the other to terminal E on reading. wire between terminal E and chassis.
the control box. Engine stationary.
~
page 5
~ ....
0' ~
VOLTMETER CONNECTION
TEST 6.
Proceed to check regulator setting.
Remove control box cover.
Isolate the battery by placing a piece of
. dry card between cut-out contacts,
alternatively, remove 'A' and A1
cables from terminals and join
together temporarily.
Connect one lead of voltmeter to ter-
minal D (or frame of regulator) and
the other lead to a good ground.
READING
-
A. With generator running at approx.
3,000 revjmin voltage should remain
constant within the following limits:
Ambient Temp. 6 volt Equip. 12 volt Equip.
10C
50F}
80- 85 160-165
20C 68F
30C 86F}
40C 104F
80 155-160
B. Voltage remains constant, but out-
side the given limits.
C. Rising volts with rising engine speed
up to 3,000 revjmin and beyond.
page 6
ACTION
Regulator in order.
Proceed to Test 7.
Adjust regulator by turning the adjust-
ing screw clockwise to increase or
counter-clockwise to lower the set-
ting. Check setting by raising speed
from zero.
Check 'D' and F' leads for short-
circuit, if O.K. suspect broken shunt
winding in regulator bobbin. The
ground lead from control box ter-
minal E is common to both shunt
windings (regulator and cut-out).
Hold a screwdriver near top of the
bobbins and test for magnetic pull.
If there is pull on the one bobbin
core and not on the other suspect
open circuit on the latter. If no pull on
either check for open circuited ground
lead. Replace defective regulator.
' ",,-,(
------------------------------------,--------------------------,------------------------------ : '.
VOLTMETER CONNECTION
TEST 6 (continued).
REGULATOR
ARMATURE
FIXI NG SCREWS
FRAME ARMATURE
. CORE
FIXED CONTACT 0 006':" 0 017 "
BRACKET WITH ARMATURE
PRESSED TO CORE
Diagram 1.
READING ACTION
..
D. Reading approx. half setting. Suspect regulator contacts not passing
E. Voltage does not rise with
engine speed, or is erratic.
page 7
current causing the contacts resistor
to be in circuit the whole time. To
test, bridge the contacts with screw-
driver. This closes the circuit between
D and F and we h o u l ~ .. get rising volts
with rising speed, -thus proving the
contacts are burnt or corroded.
Check air-gap Settings Types MCR1,
MCR2, RF95, 96, 97, RB106/1. Insert
a 0020" feeler gauge between the
crank of the armature and the L-
shaped frame, and 0012-0020" gauge
between the top of the core and the
underside of the brass shim on the
armature. Loosen the screws holding
the regulator armature to the top of
. the L-shaped frame. Press downwards
and backwards. Tighten the screws
and check that clearances are as
shown in diagram 1.
"'
."
READING ACTION VOLTMETER CONNECTION I

ARMATURE ASSEMBLY F"lXED CONTAcT
SECURING SCREWSiti------ ADJUSTMENT
/
1 -_ "_ SCREW
"TENSION
SPRING '" "I CORE
(& BI"METAl) , "
\/OLTAG AOJUSTMENl
SCREW A LOCKING 'NUT
ALTERNATIvE COPPER
SEPARATION ON
BOBBIN CORE
DISC TWO WIRES SOUAA
T YP OF SEPARATION ARMATURE
DISC OR
SQUARE - - - - 0 021' "1"' CORE
,i I ,
, Q)PPER
SEPARATION
Diagram 2.
TEST 7.
Remove card from between cut-out
contacts.
Connect voltmeter to terminal A on
control box and a good ground.
Engine stationary.
TEST 8.
Leaving voltmeter connected as for
Test 7. Start engine and watch
voltmeter.
Battery voltage.
A. As cut-out closes the reading should
increase 05 to 1 volt above battery
voltage. and increase to the regulator
setting in Test 6.
I B.
No voltage or very low voltage is
recorded when cut-out points close.
page 8
Types RF9S/3. RB106/2. RB107 and
RB108.
Slacken the fixed contact screw and
unlock armature securing screws.
Insert appropriate feeler gauge be-
tween armature and core face. Press
armature down squarely against the
gauge and re-tighten securing screws.
With gauge in position, screw the
fixed contact down until it just
touches the moving contact and
tighten lock nut, see diagram 2.
Reset the voltage adjusting screw as
described under 6B.
Proving that circuit from battery
through ammeter to A terminal is
O.K. Proceed to Test 8.
Cut-out is in order. Proceed to Test 9.
Clean and adjust cut-out contacts so
that they meet correctly.
----
,
VOLTMETER CONNECTION READING ACTION
TEST 9. A. Cut-out" points close when voltage Cut-out is in good order.
Connect one lead of voltmeter to D is within the following limits:
terminal of regulator or to the regu-
lator frame itself. 6 volt 12 volt
Other voltmeter lead to a good ground. 63-67 127-133
B. Cut-out points close outside above Adjust by turning adjusting screw in
limits. to increase or out to decrease the
setting. Re-test with voltage rising
from zero.
C. Cut-out does not close. Fit replacement unit.
THE FUNCTION O F THE FUSES IN THE AUXILIARY CI RCUITS
IN 12 VOLT SYSTEMS
Two fuses are incorporated in RF95 control boxes. The main feed is via the ammeter to the A terminal of the control
box, then through the series winding in the box to A1 terminal. Terminal A1 is also the feed to the ignition switch and from
there to A3 via internal connections in the control box through the fuse to A4 terminal. Any accessories connected to A2 will
work irrespective of the ignition switch position. Accessories connected to A4 will operate only when the ignition is switched
on.
The system is similar on RF96, RB106 and RB106/2 control boxes, but the fuses are mounted on a separate base.
page 9
<
i ~ . ~ : ..
J-: -;;j
1. ' < LQ
I .
J f'{
1 '
. li
I "
PART 3
MODEL RB310 REGULATOR - SINGLE CONTACT 3 BOBBIN TYPE
CURRENT VOLTAGE CONTROL REGULATOR TESTS WITH UNIT IN POSITION
. ,
Instruments required: Moving coil Ammeter 0-40 amperes .
Moving coil Voltmeter 0-20 volts.
The Current Regulator is adjusted. before leaving the factory. to suit the rated output of the generator which it is to
control. It is important therefore. that the Model of the generator is carefully noted before commencing the tests. This is
stamped on ~ h e yoke of the generator.
Temperature Correction Factor
. Corrections to be made to the open-circuit voltage limits when checking or adjusting settings at temperatures other
than 20C (68F) are as follows:-
For every 10C (18F) above 20e... subtract
01 volt from the 6-volt limits
02 volt from the 12-volt limits
Conversely. the same corrections must be added for every 10C below 20e.
For generator tests. repeat Tests 1 - 4. of Part 1. then proceed to Test 5. on page 11.
page 10
AMMETER CONNECTION
TEST 5: Current Regulator.
Reconnect '0' and F leads to generator
terminals. .
Remove control box cover.
Short ci rcuit voltage regulator contacts
with a crocodile clip connected
across contact plate and frame of
regulator.
Disconnect lead from terminal B (Bat-
tery) and connect this lead to nega.
tive ammeter lead.
Connect positive ammeter lead to
terminal B.
To load the generator switch on head-
lights, etc. and start engine.
READING
A. With generator at full charging
speed, approx. * 4,500 rev/ min, the
current reading is within the follow-
ing limits: *4,000 rev/min for C48.
For generator Models :
C40/1 12V:20 amps.1 amp.
C40/1
C42
(with 4f' fan).
12V:22 amps.1 amp.
(with 5" fan).
(Easidrive) 12V:35 amps. tamp.
C40AL 12V:11 amps. 1 amp.
C40L 12V:25 amps. 1t amps.
C40LQ 12V:25 amps. 1t amps.
C42 12V:30 amps. tamp.
C45PV-5 6V:33 amps.1t amps.
C45PV-5 12V:22 amps.1 amp.
C45PV-6 12V:25 amps.1 amp.
C45PVS-6 12V:25 amps. 1 amp.
C39Q 12V:19 amps. 1 amp.
C39PV-2 12V:19 amps. 1 amp.
C47 12V:30 amps.1t amps.
C48 12V:35 amps.1t amps.
(Do not switch lights on after start-
ing engine otherwise the bulbs may
burn out.)
B. Current remains constant but not
w.ithin limits.
page 11
ACTION
Current regulator is in order. Proceed
to Test 6.
Adjust regulator by turning the adjust-
ing screw clockwise to increase or
anti-clockwise to reduce the charging
rate.
.
.'
.-'
AMMETER CONNECTION
TEST 5 (continued).
CURRENT REGULATOR
AS$[.MBLY
SECuRING SCREWS -.
_ FI XED CONTACT
ADJUSTMENT
SCREW
TENS I ON
SPR I NG - - -u--'.
TYPE OF
S EP'A'RAT'iO N
DISC
CURRENT A JUSTMENT SCREW
AN D LOCK I NG NUT
A.LTERNAT I VE COPPER
SEPARA. T ION ON
B O BB I N CORE
(I)
DISC SQUARE
SQUARE
Diagram 3.
BOBB IN
CORE
READING
C. Current erratic or cannot be ad-
justed within limits.
page 12
ACTION
Check air-gap setting (see diagram 3),
unlock and screw back fixed contact
and current adjustment screws. Slack-
en off armature assembly securing
screws. Insert appropriat e gauge be-
tween armat ure and copper disc on
top of coil. Press armature down
squarely against gauge and re-tighten
securing screws.
Re-adjust current as in B and if still not
within limits, fit a replacement unit.
' f
VOLTMETER CONNECTION
TEST 6: Voltage Regulator.
Remove test ammeter and leave the B
(Battery) lead disconnected. Also
'remove clip across contact plate.
Connect voltmeter between D ter-
minal and ground.
'VOLTAGE REGULATOR
A.RMATURE
ASSEMBLY
(REAR VIEW) ALTERNATI VE COPPER
8 1- METAL
SEPARATI ON ON
BOBBIN CORE
DI SC SQUARE
(e) ( D)
BRIGHT UN PLATED (A)
OR COPPER PLATED (B )
~
i.!li
}
A+ C ..... O'OIs"}
TYPE OF SI -METAL B+ C --- . a,olS:
ANO' SEPARATION A +O - -- - OOI B
8+0 -- - -0 021"
Diagram 4.
ARMATU RE
l . ' ~
I -, '-'I
READING
A. Voltage rises steadily with generator
running at about* 3.000 rev/min.
Voltage should remain steady within
the following limits:
Ambient Temp. 6 volt CIBox 12 volt Cl Box
WC SOOF}
80-85 150-155
20C 68F
30C 86F
75-80 145-150
40C 104F
With increased speed. voltage does
not increase more than 1-1t volts.
*1.500 rev /min for C47 and C48.
B. Voltage remains constant but out-
side the given limits.
c. Voltage does not rise with engine
speed or is erratic.
page 13
ACTION
Regulator in order.
Proceed to Test 7.
Adjust regulator by turning the adjust-
ing screw clockwise to increase and
anti-clockwise to decrease the setting.
Check air-gap and adjust in similar
manner to Test 5 (C) (see diagram 4).
R,.e-adjust voltage as in B above and if
still not within limits. fit replacement,
unit.
VOLTMETER CONNECTION
TEST 6 (continued).
BOBBIN CORE
TEST 7.
IXED CONTACT
__ ~ - : o - - ADJUSTMENT
SCREW
ARMATURE ASSEM BLY I
SECUR I NG SCREWS
TENSION SPRING
VOLTAGE ADJUSTMENT SCREW
AND LOCKING NUT
Re-connect B lead to regulator. Con-
nect voltmeter to B terminal and to
a good ground. Engine stationary.
READING
D. Rising volts with rISing engine,
speed up to 3,000 rev/min and
beyond.
Battery Voltage.
page 14
ACTION
Check 'D' and F' leads for short-
circuit, if O.K. suspect broken shunt
winding in regulator bobbin. Shunt
windings on both voltage regulator
and cut-out bobbins are to common
earth. Hold a screwdriver near top
of voltage and cut-out bobbins and
test for magnetic pull.
If no pull check for open circuited
ground lead or shunt winding.
If defective fit replacement regulator.
Circuit from battery to regulator in
order.
Proceed to Test 8.
-
'" "
VOLTMETER CONNECTION READING ACTION
.
TEST 8. A. As cut-out closes, reading increases Cut-out is in order.
to 05 to 10 volts above battery Proceed to Test 9.
Leaving voltmeter connected as for voltage and increases as speed is
Test 7, start engine and slowly increased to the regulator setting
inc"rease speed and watch voltmeter. voltage in Test 6.
B. No voltage or very low voltage is
Clean and adjust cut-out contacts so
that they meet correctly. With
recorded when cut-out points close.
0010" gauge between armature and
bobbin core face contacts should be
just touching.
TEST 9. A. Cut -out points close when voltage is Cut-out in good order and correctly set
within the following limits: Proceed to FINAL CHECK.
Connect one lead of voltmeter to D
terminal of regulator and other volt- 6 volt 12 volt
meter lead to a good ground. 63-67 127-133
B. Cut-out points close outside above
Adjust by turning adjustment screw in
limits.
to increase or out to decrease setting.
:
C. Cut-out does not close. Fit replacement unit.
-
page 15
-
". - ..
' ... . .. t ' ~ v
AMMETER CONNECT!ON
TEST 10. !=INAl CHECK.
leave voltmeter connected as for
Test 9.
Insert ammeter again between terminal
B and A cable as in Test 5.
Steadily increase engine speed and
"watch both meters.
Switch on full lighting load.
33/ dia. = 238 mm.
l4/1 dia. = 198 mm.
READING
-"
As speed increases cut-out closes between
127-133 volts and charging rate builds
up with increasing speed.
Ammeter reading equals maximum rated
output of the generator.
METRIC EQUI VALENTS
0005/1 = 0127 mm.
0006/1 = 0152 mm.
0010" = 025 mm.
0-015/1 = 0-396 mm.
0-020/1 = 0-51 mm.
0-025/1 = 0-635 mm.
page 16
ACTION
0-030/1 = 0-76 mm.
0-032/1 = 0-81 mm.
0045/1 = 104 mm.
0-049/1 = 124 mm.
0-150/1 = 38 mm_
PART 4
MODEL RB340 REGULATOR - SINGLE CONTACT 3 BOBBIN TYPE
CURRENT VOLTAGE CONTROL REGULATOR TESTS W ITH UNIT IN POSITION
Instruments required : Moving Coil Ammeter 0 - 40 amperes
Moving Coil Voltmeter 0 - 20 volts
Special Tool Part No. 543 817 42
Except for adjustment of the cut-out relay drop-off voltage, which is effected by bending the fixed contact bracket
electrical settings are made by turning toothed adjustment cams carried on the front limb of each magnet frame. A special
tool is available for this purpose. Back air gaps are fixed and non-adjustable and the only mechanical settings that may be
required comprise simple adjustments to the armature-to-bobbin core air gaps.
The Current regulator is adjusted, before leaving the factory, to suit the rated output of the generator which it is to
control. The nominal setting is rubber-stamped either on the underside of the ' B-B' terminal plate or on th.e cover. In addition
a list of Lucas generators together with t heir rated output is given in the appropriate section of this booklet. The model
of the generator. which is stamped on the yoke of the machine can be noted before commencing the tests.
Temperature Correction Factor
Corrections to be made to the open-circuit voltage limits when checking or adjusting settings at temperatures other
than 20C (68F) are as follows :-
For every 10C (18F) above 20C subtract 02 volt from the 12-volt limits
Conversely. the same corrections must be added for every 10C below 20C
For generator tests. repeat Tests 1 - 4. of Part 1. then proceed to Test 5. on page 18.
page 17
AMMETER CONNECTION
TEST 5: Current Regulator.
Reconnect leads to D and F on
generator.
Remove control box cover.
Short out voltage regulator contacts
with a bulldog clip. .
Using a suitable 'jumper lead' connect
the leads to the load side of 0 - 40
ammeter.
Connect other lead of ammeter to one
of control box terminal blades B-B.
Note: It is important to ensure that
terminal B-B carries only this
one connection. All other
load connections (incl udi ng the
ignition coil feed) must be
made to the battery side of the
ammeter.
Switch on lights to ensure generator
develops its rated output.
Start engine and run generator at
4,500 rev/min (4,000 revj min for
C48).
READING
A. Ammeter pointer should be steady
and indicate a current equal to
maximum rated output of generator:
C40j1 12V:20 amps. 1 amp.
C40/1
C45PV-5
C45PV-6
C45PVS-6
C39PV-2
C47
C48
C40AL
C40L
C40LQ
C42
C42
(Easid rive)
(with 'It" dia. fan)
12V:22 amps. 1 amp.
(with 5" dia. fan)
12V:22 amps. 1 amp.
12V:25 amps. 1 amp.
12V:25 amps. 1 amp.
12V:19 amps.1 amp.
12V:30 amps. 1t amps.
12V:35 amps.1t amps.
12V:11 amps. 1 amp.
12V:25 amps.1 amp.
12V:25 amps. 1 amp.
12V:30 amps. 1t amps.
12V:35 amps. 1t amps.
B. Ammeter pointer remains steady
but current reading outside limits.
page 18
ACTION
Current regulator is in order, proceed
to Test 6.
BULL OG Cll
SHORT CIRCUITING
V R CONTACTS.
Turn the current adjustment cam until
correct setting is obtained - turning
the tool clockwise to raise the setti ng
or anti-clockwise to lower it.
/
.'
AMMETER CONNECTION READING
TEST 5 (continued),
ADJUSTMENT
CAMS
TOOL
C. An unsteady reading, i.e. pointer is
fluctuating more than 1 amp.
(CURRENT REGULATOR ADJUSTMENT)
CURRENT
VOLTAGE REGULATOR
page 19
ACTION
Check for dirty contacts, or foreign
matter in air gaps.
If in order, check air gap setting
between armature and bobbin core
as follows :-
Turn the adjustment cam to the point giving
minimum lift to the armature tensioning
spring, by turning the tool to the fullest
extent anti-clockwise.
Slacken the adjustable contact locking nut and
screw back the adjustable contact.
Insert a flat steel feeler gauge of 0045" (104
mm.) thickness between the armature and
the copper separation on the core face. The
gauge should be inserted as far back as the
two rivet heads on the underside of the
armature.
Retaining the gauge in position and pressing
squarely down on the armature, screw in the
adjustable contact until it just touches the
armatu re contact.
Re-tighten the locking nut and withdraw the
gauge.
Carry out the electrical setting procedure.
If still not within fimits fit a replacement unit.
, I
VOLTMETER CONNECTION
TEST 6: Voltage Regulator.
Remove test ammeter, and leave B-B
leads disconnected.
Note: It will be necessary to join the
ignition and battery feeds to-
gether with a suitable 'jumper
lead', to enable the engine to
be run.
Also remove bulldog clip from across
contacts.
Connect voltmeter between D ter-
minal and ground (earth).
Note: A convenient method is to
withdraw the ignition warning
light feed from control box
terminal WL and to clip volt-
meter lead of appropriate pol-
arity to the small terminal
blade then exposed, this ter-
minal being electrically com-
mon with terminal D.
Start the engine and run the generator
at 1,500 rev/min for C48, 4,500 rev/
min for C42, 3,000 rev/min all others.
READING ACTION
A. Voltmeter reading should be steady
and lie between the appropriate
Voltage regulator is in order. Proceed
to Test 7.
limits:
Ambient Temp.
10C (50F)
20C (68F)
30C (86F)
40C (104F)
Setting
149 - 155 volts
147 -153 volts
145 -151 volts
143 -149 volts
V RAND CR
ARMATURE TO BOBBIN CORE GAP
0'045"- 0049"
__ / ,..-=-,r=,
- - ~ - ~
--
-
- -
~ 1 I 1 ~
-
-
=
-
-
- -
-
- -
-
\ '
-
-
-:
CONTACT ADJUSTMENT
page 20
/
....
VOLTMETER CONNECTION
TEST 6 (continued) .
EXTERNAL SHOWN IN &ROKEN LINE
READING
B. Voltage reading remains constant
but outside appropriate limits.
C. Rising volts with rising engine, speed
up to 3,000 rev/min and beyond.
D. Voltmeter reading
fluctuates, i.e.,
poi nter fI uctuati ng
more than 03-volt.
UNTlt. UALY IN 1962, THE V;l:. I. FRAMES WERE lINKCD !,v,.. CONNECTOR THQQl."CH WHICH
( eN THE CONTACTS CLOSED POSITION) THE FIELD CURRENT PASSD. VIA TI1E C.O. I. C.R, SERIES
W'NO!NGS , TO TERMINAL '0:
page 21
ACTION
Adjust regulator by rotating the adjust-
ment cam. Turn the tool clockwise to
raise the setting or anti-clockwise to
lower it.
Check D and F leads for short-circuit, if
O.K. suspect broken shunt winding in
regulator bobbin. Shunt windings on
both voltage regulator and cut-out
bobbins are to common earth. Hold a
screwdriver near top of voltage and
cut-out bobbins and test for magnetic
pull.
If no pull check for open circuited ground
lead or shunt winding.
If defective fit replacement regulator.
Check for dirty contacts, or foreign
matter in gaps.
If in order check air gap between armature
and bobbin core face, as follows:
Turn the adjustment cam to the point giving
minimum lift to the armature tensioning
spring, by turning the tool to the fullest
_ extent anti-clockwise.
Slacken the adjustable contact locking nut and
screw back the adjustable contact.
Insert a flat steel feeler gauge of 0045" (104
mm.) thickness between the armature and
the copper separation on the core face. The
gauge should be inserted as far back as the
two rivet heads on the underside of the
armature. (continued)
VOLTMETER CONNECTION .
READING ACTION
TEST 6 (continued) D. (continued) Retaining the gauge in position and pressing
squarely down on the armature, screw in the
adjustable contact until it just touches the
armature contact.
Retighten the locking nut and withdraw t he
gauge.
Carry out the electrical setting procedure.
If still not within limits fit a replacement unit.
TEST 7. Battery voltage. Circuit from batt ery to regulator is in
With engine stationary_ Reconnect
order.
leads to B-B terminal on control box.
Proceed to Test 8.
Connect voltmeter between B-B ter-
minal and ground.
TEST 8. A. As cut-out closes, read ing rises to 05 Cut -out is in order. Proceed to Test 9.
Leave voltmeter connected as fo r to 10 volts above battery voltage,
Test 7. and continues to rise as engine speed
Start engine, and slowly increase speed, is steadily increased, unt il regulator
closely watching voltmeter dial. setting voltage, as given in Test 6, is
reached.
B. No voltage or very low voltage is
Check for dirty or burned contacts.
registered when cut-out contacts
Check for cont act al ignment.
close.
Check that they meet correctly when
armature is pressed down, the moving
contact blade should have a deflection
of 0010" - 0020".
Armature back stop to core air gap
I
should be between 0035" - 0045".
page 22
VOLTMETER CONNECTION
TEST 9: Cut-in Voltage.
Connect voltmeter between D on
control box and ground.
Switch on headlamps.
Start engine and slowly increase its
speed. Observe the voltmeter
pointer.
CUT-OUT .L
B E N ~ ~ I ' I t
ARMATURE
BACK STOP
TO ADJUST
CORE GAP.
ARMATURE TO BOBBIN CORE GAP
(0035"- 0 045")
READING
A. Voltage reading rises steadily and
then drops slightly at the instant
the contacts close. The cut-in volt-
age is that which is indicated immedi-
ately before the pointer drops back.
It should occur between the follow-
ing limits :-
126 -134 volts.
B. Cut-out contacts close outside limits.
C. Cut-out contacts will not close.
page 23
ACTION
Cut-out is in order . Proceed to Final
Check. Test 10.
Adjust cut-out by rotating the adjust-
ment cam. turn the tool clockwise to
raise the setting or anti-clockwise to
lower it.
Again check cut-in voltage.
Repeat procedure until correct setting
obtained.
Fit a replacement unit.
VOLTMETER CONNECTION
TEST 10: Drop off voltage.
Withdraw leads control box B-B
terminals.
Connect voltmeter between B-B ter-
.minals and ground.
Start engine and run up to 3,000 rev/
min.
Slowly decelerate and observe volt-
meter pointer.
READING
A. Opening of contacts, indicated by
the voltmeter pointer dropping to
zero, this should occur between the
following limits:
93 -112 volts
B. Drop-off occurs outside limits.
PHOSPHOR BRONZE
HINGE SPRING
MOVING
CONTAC.T
BLADE
(FOLLOW-THROUGH' ' &e' TERMINAL
0 ' 010-0' 020) PLATE
ARMATURE
CONTROL
SPRING
BI-METAL
i!!o--- BACKING
SPRING
ARMATURE
B A < : ~ STOP
CONTACT
BRACKET
page 24
ACTION
Control box in order.
Adjust Drop-off volts as follows :-
Stop engine, and adjust the drop-off
voltage by carefully bending the fixed
contact bracket. Reducing the con-
tact gap will raise the drop-off
voltage; increasing the gap will lower
the drop-off voltage.
Re-test and, if necessary, readjust until
the correct drop-off setting is
obtained.
Note: When drop-offvoltage is correct
the moving contact blade should
have a 'follow through' or blade
deflection of 0010" - 0020".
The armature back stop, when free,
should give a core gap of 0035"
- 0045", adjust by bending stop with
a suitable tool.
RB340 DESIGN DATA (12-volt units)
RESISTOR VALUES
(i) Contacts Resistor: Resistance
As fitted to units con-
troll i ng 12-volt generators .
having 4t ohm field
in Ohms
. windings : 37 - 43
As fitted to units con-
troll ing 12-volt generators
having 6 ohm field
windings : 55 - 65
FIELD PARALLEL
RESISTOR
(WHEN FITTED)
SWAMP RESISTOR
' B-B' TERMINAL
PLATE - - ~ - ; ; - -
Identification (i i)
Colour
Swamp Resistor:
(12-volt Units)
Measured on unit bet-
ween centre tag and
base:
Resistance in
Ohms
Yellow
Red
Replacement resistor
measured between end
tags before fitting to
unit:
(iii) Field Parallel Resist-
ance:
As fitted to units con-
trolling model C48
1325 -1425
53 - 57
CONTACTS RESISTOR generator: 37 -43
AIR GAPS
page 25
Armature back gaps (non-
adjustable) :
Armature-to-bobbin core,
VR and CR : ~
Armature-to-bobbin core,
Cut-out relay:
Follow-through' or blade
deflection of cut-out relay
moving contact :
RESISTANCE OF SHUNT
WINDINGS at 20C (68F)
Voltage
Regulator: 108-120 ohms
Cut-out: 88 - 96 ohms
ADJUSTMENT CAMS
Torque to
turn cams: 2 - 4 lb. in.
(0023 - 0046 kg m.)
Length
0030" - 0035"
(076 - 09 mm.)
0045" - 0049"
(104-124 mm.)
0035" - 0045"
(09 -104 mm.)
0010" - 0020"
(025 - 051 mm.)
CONTACT REPLACEMENT SETS
Contact replacement sets are supplied solely for use overseas,
where special service problems are encountered. The fitting of
these sets involves the replacement of existing rivets with screws.
The Part Numbers of the sets are 543 820 77-8 and 9 for the
Cut-out Relay, Voltage and Current Regulators, respectively. Each
set comprises an Armature Assembly, Clamp Plate, Fixed Contact
. Screw and Nut (or, for cut-out relays, a 'B-B' Terminal Plate
Assembly), and two 5 BA screws with associated spring washers
and lock nuts (two extra screws, spring washers and lock nuts being
provided for the cut-out relay to secure the above terminal plate
assembly).
IDENTIFICATION OF ARMATURE ASSEMBLIES
(i) Cut-out relay
armature:
(i i) Voltage regulator
armature :
(iii) Current regulator
armature:
Moving contact carried on phosphor bronze
blade.
Phosphor bronze hinge spring unpierced.
Blued steel control spring backed with
bi-metal spring (high expansion side lower-
most).
Bi-metal hinge spring pierced with central
01 SO' (38 mm.) hole. (High expansion
side of bi-metal uppermost).
Blued steel hing! spring, unpierced.
FITTING ARMATURE ASSEMBLIES
(i) Carefully remove existing rivets, using a file, centre-punch,
twist drill (;&" diameter; 238 mm.), and a parallel-sided
' punch (-1./ diameter; 198 mm.), in that order.
page 26
(ii) Discard original armature, clamp plate, and fixed contact
screw and nut, or, when replacing a cut-out relay armature,
the 'B-B' terminal plate.
(iii) Loosely assemble replacement parts to magnet frame, noting
that the armature hinge spring has open-ended slotted fixing
holes to facilitate fitting under the clamp plate .
Do not insert the fixed contact screw of the VR or CR more
than 1-!- to 2 turns at this stage.
(iv) When applicable, fit and tighten replacement 'B-B' terminal
plate, inserting the securing screws from the supper side of
the control box base plate.
(v) Insert a 003r (081 mm.) feeler gauge approximately half-way
up the back air gap.
(Vi) Insert a 0045" (104 mm.) feeler gauge in the armature-to-
bobbin core gap as far back as the two tension spring rivets.
(vii) Press the armature squarely down towards the bobbin core
and back towards the magnet frame, firmly trapping both
gauges.
(viii) Tighten the armature assembly securing screws.
(ix) Withdraw gauges and carry out mechanical and electrica:l
adjustments.
ADJUSTMENT SEQUENCE.
After fitting a replacement contact set (or sets), the regulator or
cut-out relay concerned must be adjusted both mechanically and
electrically. The order of electrical settings (when all three arma-
tures have been replaced) being, first, the voltage regulator, secondly
the cut-out relay and, thirdly, the current regulator.