p48 (7)
ELECTRICAL SYSTEM
this field is energized and generator output
ILLUS. 35
TESTING REGULATING FIELD COIL
Electrical system is a 6 volt, one wire, ground return system, with negative ground. Generator is third brush and "lamp load" regulating type. Lamp load regulation is accomplished by connecting "shunt" field winding in the lighting Circuit. When lights are tumed "ON " xŁS- 5 “J 1 A A
is increased to carry load of lighting eguipment.
When Generator Fails to Charge
When generator apparently quits charging (indi-cated by green signal light in switch panel staying lit or battery going dead), the trouble may be of such naturę that repairs can be madę without removing generator. Follow procedurę outlined below, step by step, until the trouble is located.
1. Test the battery and if its condition is ąuestion-able, replace with fully charged battery before mak-ing further tests.
2. Remove left footboard, footboard sidebar and clutch footpedal assembly.
3. Remove generator end cover and inspect brushes to make surę they are not wora out, broken, or gummy and sticking in brush holders.
4. See that commutator is not excessively oily, dirty or gummy.
5. Make surę brush holders are not bent and pos-sibly striking shoulder on commutator.
Testing Field Coils and Brush Holders Without Disassembling Generator
Caution: Overloading ammeter, due to short Circuit or otherwise, will damage it. Overload is indi-cated by needle going beyond rangę of calibrated scalę; direct "short" is indicated by needle swinging violently to extreme limit of its travel. In either case, contact must be broken instantaneously to avoid damaging or buming out ammeter. Therefore, in making the following tests with ammeter, first make only a momentary contact to determine if a short exists. If ammeter needle does not go beyond calibrated scalę, it is safe to make continuous contact and proceed with test as described.
As an added precaution, in making tests with ammeter, always work on a bench with an insulated top. This will prevent shorting through bench top.
Never touch test points together.
Connect a łully charged battery to suitable test ammeter and test points as shown in Illustration 35.
Remove the three brushes from their holders (See "Inspecting or Replacing Generator Brushes," Page 51). Removing main brushes reąuires removing screws connecting field coil terminal wires to brush holders. These wires must be reconnected before tests can be madę.
Testing regulating field coil (see Illustration 35):
1. Touch test point "A" to "relay" terminal of generator and test point "B" to third (regulating) brush holder as shown in Illustration 35. The ammeter should read between 1.4 and 1.9 amperes. If ammeter shows no reading, field coil is open (See that terminal connections are tight and field coil wires are not broken at terminals). If reading is appre-ciably higher than 1.9 amperes, field coil is shorted intemally.
2. With test point "A" still on "relay" terminal, ground other test point by moving it to generator frame, as indicated by dotted lines "C," Illustration
6. If the fault is not found through above checks, it may be in the cutout relay, or in wiring between generator and battery.
To check whether trouble is in generator, relay, or wiring between relay and battery:
1. Connect an ammeter between battery negative terminal and ground.
2. Disconnect wires from "relay" terminal of generator and battery positive terminal, and connect a jumper wire directly between these two terminals.
. 3. Start and speed up engine and check reading of ammeter. If generator shows normal charge, trouble is in cut-out relay (See "Cut-out Relay," Page 52) or in wiring between relay and battery (See "Wiring Details," Page 54). If generator shows no charge, it must be removed for further attention.
Removing Generator
1. Disconnect wires from generator "switch" and "relay" terminals.
2. Remove the two long screws, through timing gear case cover, that secure end of generator against gear case.
3. Remove nut, lock washer and curved washer from end of strap that clamps generator in its cradle on crankcase.
4. Lift strap high enough to permit raising generator so oil slinger (on end of generator gear) will elear adjacent gear and allow generator to be removed from engine.
5. Be surę to observe and count number of paper shims between generator and cradle. Lay these shims aside to be used again when generator is re-installed. Also, notę location of hole in shims for oil drain. These shims were reąuired in original assembly to adjust driving gears for proper mesh and, if left out, gears are still likely to mesh too deeply and howl, even though they have seen con-siderable service.
6. Unless a new generator gasket is available, to be used when generator is re-installed, be careful about damaging the old one.
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