CHARGING SYSTEM CIRCUIT
The generator features a solid state regulator that is mounted inside the generator. All regulator components are enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the rear housing. The regulator voltage setting cannot be adjusted. The generator rotor bearings contain enough grease to eliminate the need for periodic lubrication. Two brushes carry current through the two slip rings to the field coil mounted on the rotor, and under normal conditions will provide long period of attention free service. The stator windings are assembled inside a laminated core that forms part of the generator frame. A rectifier bridge connected to the stator windings contains diodes, and electrically changes the stator AC voltages to a DC voltage which appears at the generator output terminal. The neutral diodes serve to convert the voltage fluctuation at the neutral point to direct current for increasing the generator output. (Scheme 29)
Scheme 29
Load Check (80A/105A)
Run engine at 2000 rpm and turn on head light and heater motor. Measure current and if it is less than 30 A, repair or replace generator.
BRUSH & BRUSH HOLDER
Check each brush for wear by measuring its length. If brush is found worn down to service limit, replace brush. See GENERATOR SPECIFICATIONS. (Scheme 30)or (Scheme 31).
Scheme 30
Scheme 31
70A
Testing information for 70A is not available from manufacturer.
80A/105A
- Check that drive and bearing is not rough or worn. see scheme 40
- Check that end housing bearing is not rough or worn. see scheme 39
Using capacitor tester, check capacity of condenser, located on rectifier. (Scheme 32) Replace rectifier if condenser capacity is not.5 uF.
Scheme 32
Testing information for 80A/105A model is not available from manufacturer.
- Using ohmmeter, check continuity between each of upper and lower rectifier bodies and each diode lead (2). Check both directions by reversing probes of ohmmeter and there should be only one way continuity in each case. If check result is not satisfactory, replace the rectifier (1).
- In the same manner as described in above step 1, check that there is only one way continuity between both leads of diode trio. (Scheme 33)
Scheme 33
- Positive rectifier (Scheme 34)Using an ohmmeter, connect one tester probe to the "B" terminal (1) and the other to each rectifier terminal (2). Reverse the polarity of the tester probes and repeat step No. 1. Check that one shows continuity and the other shows no continuity. If there is continuity, replace rectifier.
- Negative rectifier Using an ohmmeter, connect one tester probe to each negative terminal (1) and the other to each rectifier terminal (2). (Scheme 34) Reverse the polarity of the tester probes and repeat step No. 1. Check that one shows continuity and the other shows no continuity. If there is continuity, replace the rectifier.
Scheme 34
ROTOR
- To test rotor for an open circuit, use ohmmeter to check for continuity between slip rings of rotor. If there is no continuity, replace the rotor (1). (Scheme 35)
- Using ohmmeter, check that there is no continuity between slip ring and rotor core. If there is continuity, replace rotor (1). (Scheme 35)
- Check slip rings for roughness or scoring. If rough or scored, replace the rotor.
- Using a vernier caliper, measure the slip ring diameter. If the diameter is less than minimum, replace the rotor (80A/105A). (Scheme 36)
Scheme 35
Scheme 36
STATOR
- To test stator for an open circuit, use ohmmeter to check all leads for continuity. If there is no continuity, replace the stator (1). (Scheme 37)or (Scheme 38).
- Using Ohmmeter, check that there is no continuity between coil leads (2) and stator core (1). If there is continuity, replace stator. (Scheme 37)or (Scheme 38).
Scheme 37
Scheme 38
Diassembly (80A/105A)
- Remove "B" terminal inner nut (3) and insulator (2).
- Remove rear end cover (1). (Scheme 40)
- Remove 2 screws (3) and pull out brush holder assembly (4).
- Remove 3 screws (1) and IC regulator (2).
- Remove brush holder cover from brush holder. (Scheme 41)
- Remove 4 screws, 1 bolt and rectifier (1). (Scheme 42)
- Remove 4 rubber insulators (1). (Scheme 43)
- Hold shaft by using hexagonal box wrench (2) and remove pulley nut, and pull out pulley (1). (Scheme 44)
- Remove 4 rear end frame nuts (3).
- Drive out rear end frame (1) with tapping rotor shaft (2) lightly by using plastic hammer (4).
- Separate rear end frame (1) from rotor evenly by using plastic hammer (4). (Scheme 45)
- If required, use bearing puller (2) to remove end housing bearing (1) and bearing cover (3). see scheme 38
- If required, remove 4 screws, retainer plate (2) and drive out drive end bearing (3).
- If required, remove stud bolts (1) and then pull out stator (4). see scheme 40
