Bulletin 1G-150Delc<>-Re:n:1Y

ANDERSON. iNDiANA. U.S.A.

SERVICE

Date 7.3.61

Page 110 Pages

File Under:BULLETING.GENERATORS

-SIIpe"ed.. Bulletin 10.1 SO

Dated 3.24-53

ADJUSTMENTS,TESTSAND MAINTENANCE OF

D.C. GENERATORS

-.

.....

GROUNDSCREW

'\HINGE

CAPOilER

Fiaute I-Typic:al D.C. Gene~tOf.

INTRODUCTION

Delco-Remy d.c. generators are manufactured ina wide range of sizes and types, but the basic d~sign of each generator is the same. Regardless ofsize, each generator has an armature mounted atboth ends on bearings. The armature rotates be.tween pole shoes over which are wound field coils.The voltage and current developed in the arma.ture windings is supplied through brushes ridingon a commutator to the generator terminals, andthen to the battery and other electrical accessoriesin the circuit. Since all d.c. generators adhere tothe same basic design, the maintenance and test-ing procedures for aU sizes are similar. A typicalgenerator is shown in Figure 1.

This bulletin covers the different types and designsof d.c. generators along with recommended serviceprocedures for each. The subject of OperatingPrinciples is covered in Delco-Remy TrainingChart Manual DR-5133E.

co: 1.2. I WDS. I'S, I.n, 131. 132: 16. If 0

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TYPES AND DESIGNS

The following cross sectional views illustrate thevarious types of generators manufactured byDelco-Remy.

The extruded frame two-brush two-pole type ofgenerator shown in Figure 2 has a frame diametersize of 4% inches. Each end frame has hinge capoilers for periodic lubrication, and the commu-tator end frame features a bronze bushing and anoU reservoir. Continuous lubrication to the bush-ing and shaft is provided by a wick which extendsthrough a hole in the bushing to contact the shaft.A special version in the 4% inch frame diametersize is the generator shown in Figure 3. This as-sembly features a blast tube for forced air cooling,and sealed ball bearings in each end frame whichare lubricated for the life of the bearing.

The generator shown in Figure 4 has a frcu:nedi-ameter size of 51/8inches. It features ball bearings

!"'I"UD IN 1I.5.A.

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Service Bulletin IG..150

~Page2

D.C.GENERATORS

r""'" POI.E SHOE

i ,-POlE SHOESCREW! I1 ! INSULATION 7 ,-OILER

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(BAll SEARINGflElO COIL, - !

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i / Ii WOOOR,

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THRl/ IJ' r""Tmm_"\'>-COMMUTATOR j ARMATUREBOLT...!. \ I ..- LSPRING

Oil,oJ k SEAL ,..

~~ 4-'.(!~tpu:m AND~;~:: fAN

, "I LLCOMMUTATORENDfRAME ORIVEENDFRAME

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.

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DRIVE END FRAME

\ ' \\.BRUSHj

COVERSAND ICOMMUTATOR IEND FRAME.:J

and hinge cap oilers in each end frame,and acover band which can be removed for easy inspec-tion of the brushes and commutator. This genera~tor is of the two-brush two~pole type.

In Figure 5 is illustrated a two~brush two-polegenerator which is similar in construction butlarger in size than the assembly shown in Figure4. This generator has a frame diameter of 5% or

5% inches and a cover band that can be removed"to permit easy inspection of the brushes and com",-mutator.

The generator illustrated in Figure {) has twobrushes, two poles, and a frame diameter size of5% or 5% inches. This type generator featuresgrease reservoirs providing permanent-type lubri-

OilER

I

I l BEARING FIELD COIL0-, '

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,

COMMUTATORH END FRAME

ARMATURE ! (DRIVE END--W

,

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.FRAME H~J

PUllEYAND FAN

FigUre 4-Cross sectional view of typical $!,jj"frame diameter generator.

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~Service Bulletin 1G.150

Page 3

D.C. GENERATORS

OilER ;1

BEARING~- , :TI~,

I

i d;,J.;

ARMATURE ,

DRIVE END'1jFRAME

FilrUl'e ~ross sectional view of typical generator having frame diameterof 5%" or S~".

cation, and extra long brushes with special con~stant-tension brush springs. These design featureseliminate the need for periodic lubrication andbrush replacement between engine overhaulperiods. Cover plates which are mounted overwindows in the field frame can be easily removedfor inspection of the brushes and commutator.

The assembly shown in Figure 7 has a frame di-0 ameter size of 6n inches.The ball bearings in each

end frame in this generator are sealed for life,and no periodic generator lubrication is required.Generators in this frame size have four poles, andsome models have two brushes whereas. othershave four brushes. .

! GREA.

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.

SERVOIR

\ HEAVY.DUTY

\ BAll BEARING ...I ~

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.. L-IIiiSPECTIONWINDOW SEAL '-~ AND COVER PLATE ......

, "'--REPLACEABLE MOUNTING BUSHING~

FIIrUI'e &-Cross sectional view of 5%" or $%" frame diameter generator with specialbrushes and pemument bearing lubrication.

Service, Bulletin 1G..150r7""=:-'

. +ll!?))Li'-'~'~<"--Page4

D.C. GENERATORS

~I :

BEARING

ARMATURE ISEARING ""'" COMMVTATOR FIElD COILEND FRAME

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Figure 7-Cr()$$ sectional view of typical Gn" frnme diameter generator.

The generator illustrated in Figure 8 is afour~brush four-pole unit having a frame diameter of61'\ inches. On this type generator, a roller hear~ing is used in the drive end frame, and a ball bear~ing in the commutator end frame. The inner raceof the ball bearing is secured to the shaft with anut threaded oyer the shaft at the commutatorend. Grease cups afe used on each end frame forperiodic lubrication.

The assembly io Figure 9 has four brushes andfour poles and a frame diameter of 8i~ inches.00 some models the four neld coils aTe connectedin series, and io other models a split field arrange-ment is used as shown in Figure 17. Provision ismade on the commutator end frame for attach-ment of a filter screen to remove dust, dirt, andother foreign material from the cooling air drawn

POU SHOE if GREASECUP, aC-"'fu

, -FAN

COMMUTATOREND FRAME ARMATURE

FIgure g Cross sectional view of Iyplcal Ih"," frame diameter generlltor.

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Service Bulletin IG.150

Page 5

D.C. GENERATORS

FIELDTERMINAL(F. J)GREASE ARMATURE-

/CUP TERMINAL GROUND TERMINAL

~, .:~ ~ j(C"ELO~~~L~ IF-2).. -A '.. ,_.U_-JJ. !I.;,

/GREASE CUP

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~BRU&H

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COVER BAND ARMATUREBAll BEARING

COMMUTATOREND FRAME

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Figure 9-Cross sectional view of typkal 8!~1" frame diameter generator withsplit fields.

through the generator by the fan. Ball bearingsare used in each end frame, and lubrication isprovided by grease cups.

The generator shown in Figure 10 is also of theStir inch frame diameter type, but the frame lengthis shorter as compared to the assembly pictured

in Figure 9. This type generator also has greasecups and a filter cover, but uses a roller bearingin the drive end frame with a ball bearing in thecommutator end frame. This type assembly fea-tures six brushes and six poles, along with threeinterpoles connected ill series with each other.(See Figure 15.)

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\ G.OUHO TE.MIN4l Ie1

.~j - alE4SE cu,

DRIVE END !!lAME

CO_UT4TO. 4.IMTU.E IHfRI'OI.E COIl

Figure IO--Cross sectional view of typical 8p~" frame diameter geMrator havingsix poles.

Service Bulletin 1G.150Page 6

D.C. GENERATORS ~I~""-

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MAINTENANCE

Maintenance procedures may be divided into twosections-Lubrication and Inspection.

LubricatiQn

It is very important that proper lubrication pro~cedures be followed in order to obtain maximumlife from the generator.

All bearings used in generators use grease to re~tain the oil which bleeds to the bearing surfaces toprovide proper lubrication. On some generatormodel<; hinge cap oilers are used so that the oilsupply in the grease can be replenished. Othermodels feature grease cups which permit directapplication of additional grease to the bearing asthe original supply becomes exhausted. Some gen~erators contain a .built~in reserve supply of greasein a reservoir located in the generator end frame,and others use bearings which are sealed on bothsides to retain the original grease supply.

On generators having hinge cap oilers, a few dropsof SAE No. 20 oil should be added at vehicle orengine lubrication periods. Generators with greasecups should have the grease cups turned downone full turn at vehicle or engine lubrication per-iods. Generators having sealed bearings, and thosewith grease reservoirs in the end frames, requireno periodic lubrication, and are designed to oper~ate between engine or generator overhaul periodswithout lubrication attention.

There are two types of grease recommended forbearings in d.c. generators. For generators of thetype shown in Figures 2 and 4, any high gradegrease of reputable manufacture is satisfactory,Od these types of generators, the bearing shouldbe refilled only one-quarter full, so that the ballsare completely covered but the separator remainsexposed. ALso grease reservoirs should be onlyhaLffined with grease so that when the generatoris reassembled, the reservoir will be only half~filled.

CAUTION: OverfULing will cause the bearing tooverheat, resuLting in prematt//re failure. Keep lu-bricants perfectLy dean, as the sma.Uest amount ofdirt or other foreign matter in a bearing will causepre11w-Curefailure.

For other d.c. generators such as those shown inFigures 5, 6, 8, 9 and 10, Delco~Remy lubricantNo. 1948791 is recommended. On these types Qfgenerators, the bearing may be reused if the 8eT~vice miLeage .is !.ow and if 0.reasonable amount ofthe grease suppLy in the bearing remains, and ifthe bearing is otherv.'ise not defective. However, ifthe grease supply in the bearing is ne.arly or com~pleteIy exhausted, it should be replaced with anew bearing. CAUTION: Do not add grease to abearing used on these types' of generators. Always

replace with a new bearing instead of addinggrease tQ the old bearing. On these generators,No. 1948791 grease may be added to the greasecups and to the reservoirs in the end frames asrequired.

CAUTION: Add on~y enough grease to the reser-voirs so t1ur.twhen the generator is reassemMed,the reservoir witt be only ha~f~filled. Overfillingwill caU$e the bearing to overheat, resttltinginpremature failure. Keep lubricants perfectLy clean,as the smaUest amount Qf dirt or other foreignmatter in a bearing will Cause prema.ture failure.

The generators shown in Figures 3 and 7 havesealed bearings. On this type of assembly, no per-iodic .lubrication is required, and the bearingsshould be.replaced at engine overhaul periods.

Inspection

Inspection procedures are limited mostly to visualchecks for loose mOWlting bolts, a loose drive belt,damaged wiring, and worn commutator brushes.

All mOWlting bolts should be kept tight, and thebelt tension should be adjusted to conform withengine or vehicle manufacturer's recommenda~tions.

Wiring with frayed insulation should be replaced,and aU connections should be checked for tight-ness and cleanliness.

If the commutator is dirty, it may be cleaned withNo, ao sandpaper, or with a brush seating stone,with the generator in operation. Blow away alldust after the cleaning operation. If the commu~tator is rough, out of round, or has high mica, thearmature must be removed so the commutator can

" be turned down in a lathe and the insulation be-tween bars Wldercut. Remove only enough ma-terial to make the commutator smooth and round,and undercut the insulation 1/32 inch deep and

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Figure l1~Measur1ng b~h sprin( tension on genera.lors ofIhe type shown in Figure 1.

-+ITTIL-Service Bulletin 1G..150

Page 7

D.C. GENERATORS

!IWIIMInH IWllIIUSK-'_1 c-

FtlUm12

<OMMUTATOIfU ~

1

POUIItOfI --I

f

regulator for output control, and this gener-ator is used in a wide variety of applicationshaving low to moderate current output re-quirements.

f. The insulated generator circuit (Fig. 14)has both brushes connected to terminals onthe generator frame. This type generator isused with a wire return from the batteryand other accessories, in place of using the

flUDCOIL POLESHOEvehicle frame and engine block as the re-FIlUm14 turn circuit.

IWIIIIIISII IWllIIUSHiJ!!W1ItJ (-

FIlUm13.033 inch wide. Finish with No. 00 sandpaper, andblow away all dust, particularly between bars.

If the brushes are worn down to less than halftheir original length, they should be replaced.New brushes can be seated to make good conta.ctwith the commutator by holding a brush seatingstone on the commutator with the generator inoperation or by applying brush seating compoundto the commutator. Blow away all dust after theseating operation.

A visual inspection will often reveal the condi-tion of the brush springs. If the springs are cor-roded, or if. they are blued and discolored fromexcessive heat, they should be replaced. If thebrush arms move freely, and if the brush moveSfreely in the holder, with no spring corrosion ordiscoloration, the springs most likely are satis-factory. If an additional check is-desired, use aspring tension scale to measure the brush springtension, and compare with specifications given inBulletins IG~180, 1G-185 and 1G-186. The methodof checking the spring tension on generators Qfthetype shown in Figure 1 is illustrated in Figure 11.The spring gauge should be hooked under thebrush arm where it contacts .the brush, and thereading taken when the brush arm first starts tomove off the brush.

GENERATOR CIRCUITS

The generator circuit shown in Figure 15 has inter-pole windings which minimize distortion of themagnetic fields at different generator outputs.While distortion of the magnetic fields 'is normal,this type of generator supplies such high currentoutputs that the distortion would be excessive,causing poor commutation and short brush life.The interpole windings reduce distortion andassure good brush life.

The generator circuit shown in Figure 16 has abucking field coil which is connected across thegenerator armature. The magnetism produced bythe bucking field coil opposes the magnetismcreated by the main field coil. On generators ofthis type, only a small amount of magnetism isneeded at high generator speeds for the generatorto produce specified voltage. Since the main fieldmagnetism and bucking field magnetism opposeeach other, the current through both of these wind-ings remains at a normpllevel at high speeds, butthe opposing effect results in the small magneticfield needed at these speeds. With the normalamount of current in the main field windings athigh speeds, the regulator is able to retain voltagecontrol. Without the bucking field, the main fieldcurrent would have to decrease to an abnormallylow value at high speeds. At such a low value, theregulator would not be able to control the voltage.

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 Iill FIgure 12. ThlS type of CU:CUltarrange-ment provides automatic control of the gen- ~eratoI' output, thereby eliminating in mostcases the need for a voltage regulator con-trol. However, this type of generator islimited to applications requiring lower cur-rent outputs.

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The shunt type generator circuit shown inFigure 13 requires a voltage and current

IIITIRPOU (01

Figu~ 15

IU<DIG f\IUI (01

Figum 16

Service Bulletin 1G..150

Pogo8

D.C. GENERATORS~

<OIIMUTAfOl

(ONTACT roINn\

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VOL TMeTER

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FIgure 13-UA" circuitgenerator.

Figure 19-"B" circuitgenerator.

rent regulators. On this type of generator, highcurrent outputs are obtained at engine idle speed.For a more detailed description of the generatorcircuits shown above, see the Delco-Rerriy Train-ing Chart Manua~ DR-5133E.

"A" Circuit and "B" Circuit-The generator cir-cuits shown in Figures 12 through 17 can be classi-fied as either "An circuit or "B" circuit. An "Aucircuit generator is shown in Figure 18. In thistype circuit, the field winding is connected to theinsulated brush inside the generator and is con-nected to ground through the contact points in theregulator. In the "B" circuit generator (Fig. 19),the field winding is grounded inside the generator,and is connected to the armature circuit inside theregulator.

The insulated generator circuit shown in Figure14 may be used either as an "An circuit or "B"circuit generator. If the "AI" terminal is connectedto the regulator, and the "A2" terminal is groundedor connected to the battery re~um circuit, the gen-erator be<:omes an "A" circuit type. If the "A2"terminal is connected to the regulator, and the"AI" terminal is grounded or connected to thebattery return circuit, the generator becomes a"B" circuit type.

The type of circuit for each generator model islisted in the Test Specification Bulletins lG-1SO,IG-185, and IG-186.

F A

<::::::::J

AMMeTER

GENERATOR"A" CIRCUIT

OUTPUT CHECKS

(Refer to Service Bulletins 1G.180, 1G.185 and16.186 for Specifications)

To check the generator for electrical output, con-nect an ammeter in series with a battery to thegenerator output terminal. Also connect a volt.meter from the generator output terminal toground, and a load rheostat across the battery.Refer to the above Service Bulletins to determineif the generator is "A" circuit or "Bu circuit. Thenconnect a jumper lead to the generator field ter.minal as shown in Figure 20 for "A" circuits, andas shown in' Figure 21 for liB" circuits. Operatethe generator at specified speed, and adjust theload rheostat as required to obtain the specifiedoutput.

If the generator does not perform according tospecifications, it should be disassembled forfurther testing.

DISASSEMBLY

Generator disassembly can be accomplished firstby removing the thru-bolts, or end frame attachingbolts, and then separating the two end frame as.semblies from the field frame. On some models, itis necessary to detach leads from the brush holdersbefore the commutator end frame can be removed.Also, on generators of the type shown in Figure 8,the commutator end frame retainer plate, and thecotter pin and nut on the shaft, must be removedbefore the end frame can be separated from thefield frame.

When removing bearings from the armature shaftor end frame, care should be taken to avoid dam-age to the balls and raceways. If the bearing is apress fit over the shaft, use bearing pullers againstthe inner race only. If the inner race is inacces.sible, and it is necessary to pull against the outerrace, the balls will be loaded and may be damaged.Similarly, when removing a bearing whose outer

race is a press fit into theend frame, use an arborpress against the outerrace to avoid loading theballs.

Deleo After bearing removal,wash in a clean solvent,and carefully inspect forworn surfaces, looseness,broken se par a tor s, acracked ring or race, anda rough or catchy feeling.Always replace any bear-ing if its condition isdoubtful.

BATTERY

Figure ~<>mUi'~Uqj'!S for dle<:ki.ng output (>1)"/4." drcult senerato....

~Service Bulletin 1G-150

Page9

D.C. GENERATORS

JUMPERLEAD

lOADRHEOSTAT

(::j

AMMETER

VOLTMETER

GENERATOR"B" CIRCUIT

De1,oo

The generator field wind.ings should he checked forshorts, grounds and opens.To check for shorts, con~nect an ammeter and bat~tery in series with thefield windings, and referto Service BulletinsIG-180, 10~185,and 10-186 for specifications. Ifthe current reading ishigher than specified, thewindings are shorted.

SATTERY

To check the field wind-ings for grounds, connectone prod of a 110 volttest lamp to the fieldterminal, and the otherprod to the generator

frame. If the lamp lights., the windings aregrounded. On "B" circuit generators, the groundlead must be detached from the frame when check-ing for grounded fields.

To check the field windings for opens, connect the110 volt test lamp prods across the windings. Ifthe lamp fails to light, the windings are open.

A shorted, grounded, or open field will result inabnormal generator output. A shorted field wind-ing will cause excessive burning of the voltageregulator contact pQints, resulting in reduced gen-erator output. An open field winding will resultin no generator output. A grounded field cancause excessive generator output on "A" circuit

1'5,if the ground is near the "F" terminal.the ground is near the end of the winding con-

nected to the insulated brush, reduced generatoroutput will be obtained. On "B" circuit generators,a grounded .field will cause exces$ive pitting andburning of the voltage regulator contact points,resulting in reduced generator 'output.

On "bucking field" generators (Fig. 7), a shorted,grounded, or open bucking field winding can causeexcessive generator voltage at high .$peeds.

Flr~l'!! 21-Conneetlonsforcheeking iJ>utputon "8" cireult generatol'$.

IMPORTANT-ReteT to the section entitled"MAINTENANCE" tOT proper i'/Lbric4tion proce-d'/LTes. .

When remounting bearings, use an arbor pressand pre.ssfirmly and evenly against the properrace to avoid loading the balls. If the mouniingsurfaces are dean, and the bearing is startedproperly and is not cocked or mis-aligned, it canbe mounted without undue pressure.

Grease and oil seals should he replaced after ap-.preciable mileage, 01' if the seal is worn or dam-aged in any way.

ELECTRICAL TESTS

After the generator has been disassembled, testscan be made of the armature andneld coils todetermine any electrical defects.

The armature should be ch~ked for shorts,grounds, and opens. To check for shorts, place thearmature in a growler, and slowly rotate with ametal blade held on the armature. If the metalblade vibrates, the windings are shorted.

To check the armature for grounds, touch oneprod of a 110 volt test lamp to the commutator,and th

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other test lamp P.

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..

d to the sh.

aft or lami-nations. If the lamp lights, the windings aregrounded.

To check the armature for opens, visually inspectthe wiring connections to the commutator bars,and inspect the commutator for a burned or dis-colored commutator bar. An open circuit willcause one of the bars to burn and become dis-colored. Also,the armature maybe checked foropens ona growler meter. If the meter reads low,the winding connected to the commutator barsto which the prods are connected is open.

~

REASSEMBLY

Reassembly is the reverse of disassembly. Careshould be taken to avoid damage to grease sealsand oil seals during reassembly, and the brushesshould be checked after reassembly to make surethey are free in their holders and the brush armsmove£reely.

THIRD BRUSH ADJUSTMENT

On some generators, the third brush location canbe adjusted by loosening the third brush ringclamping screws, and then moving the third brushin the direction of rotation or in the opposite direc~tion. Moving the brush in the direction of rotation

Service Bulletin 1G.150

Page 10

D.C. GENERA TORS ~will increase generator output, and in the oppositedirection will decrease generator output. If thebattery remains consistently undercharged orovercharged, relocating the third brush may cor-rect the condition.

CHECKING AND ADJUSTINGNEUTRAL POINT

Many of the higher output shunt generators haveadjustable brush plates which can be shifted toobtain the proper brush locations with respect tothe neutral point. Proper adjustment is necessaryin order to obtain best commutation and thereforemaximum brush and commutator life. The neutralpoint refers to a particular relationship betweenthe poles, armat\1re windings and brushes. Whenthe relationship of these parts is correct, minimumarcing and best commutation will be obtained.Whenever new brushes, armature, or poles areinstalled, or whenever a generator has been dis-assembled, the brush position must be checkedand adjusted as follows:

With the generator assembled and the brush ringattaching screws just tight enough to hold thebrush ring in place in the commutator end frame,connect a battery between the generator" A" ter-minal and ground (or between the "Al" and "A2"terminals on insulated units) and note the ten-dency for the armature to rotate. The generatorshould be on a test bench with the armature freeto rotate and without any connection to the gen-erator field terminal The voltage to use in makingthis check is the minimum amount of voltage whichwill cause the armature to rotate when it is freeto turn. This voltage may be obtained by connect-ing a variable resistance into the circuit from thebattery. The neutral point is found by shifting thebrushes into the position at which there is no ten-dency for the armature to rotate in either direc-tion. If the generator has interpoles the brush

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setting must be exactly on the neutral point. Gen-erators without interpoles must have the brushesshifted ahead 114commutator bar width in thedirection of armature rotation so that the arma-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 platelocking or attaching screws should be tightenedsecurely.

POLARIZING GENERATOR

After a generator has been tested and repaired,and installed on the engine or vehicle, it must bepolarized so it will have the co.rrect polarity withrespect to the battery polarity. Failure to polarizethe generator may result in burned or stuck cut-out relay contacts in the regulator, along withdamage to the wiring and generator windings.

"A" Circuit Generator-To polarize an "A" circuitgenerator, momentarily connect a jumper lead be-tween the regulator BATTERY and ARMATUREterminals after all leads have been connected, hutbefore the engine is started. If the generator is a24 or 32 volt unit, temporarily insulate the groundbrush or brushes from the commutator to avoidexcessive current through the armature. Thebrushes can be temporarily insulated from thecommutator with a piece of cardboard or othersuitable insulating material.

-II

I

-I

"S" Circuit Generator-To polarize a "B" circuitgenerator, disconnect the lead from the regulatorFIELD terminal, and momentarily touch the leadto the regulator BATTERY te1iffiinal. This shouldbe done after all other leads have been connectedand before the engine is started.

Polarizing the generator allows a surge of currentto flow through the field windings, which insuresthat the polarity of the generator will match thepolarity of the battery.

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