GENERATOR INSPECTION

PROCEDURE


  1. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY


    1. B003K5UC11
      *a Length

      Using a vernier caliper, measure the brush length.

      Standard length
      9.5 to 11.5 mm (0.374 to 0.453 in.)
      Minimum length
      4.5 mm (0.177 in.)

      If the length is less than the minimum, replace the generator brush holder assembly.

  2. INSPECT GENERATOR ROTOR ASSEMBLY


    1. B003R89

      Check that the generator rotor bearing is not rough or worn and that it rotates smoothly.

      If necessary, replace the generator rotor assembly.

    2. B003OEDC20
      *a Slip Ring

      Check the generator rotor assembly for an open circuit.


      1. Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Slip ring - Slip ring 20°C (68°F) 2.1 to 2.5 Ω

        If the result is not as specified, replace the generator rotor assembly.

    3. B003PVJC18
      *a Rotor Core
      *b Slip Ring

      Check if the generator rotor assembly is grounded.


      1. Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Rotor core - Slip ring Always 10 MΩ or higher

        If the result is not as specified, replace the generator rotor assembly.

    4. Check each slip ring.


      1. Check that the slip rings are not rough or scored.

        If the slip rings are rough or scored, replace the generator rotor assembly.

      2. B003P3IC03
        *a Diameter

        Using a vernier caliper, measure the slip ring diameter.

        Standard diameter
        14.2 to 14.8 mm (0.559 to 0.583 in.)
        Minimum diameter
        14.0 mm (0.551 in.)

        If the diameter is less than the minimum, replace the generator rotor assembly.

  3. INSPECT GENERATOR DRIVE END FRAME


    1. B003N6UC02
      *a Coil Lead

      Check the stator for an open circuit.


      1. Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Coil lead - Coil lead Always Below 1 Ω

        If the result is not as specified, replace the generator assembly.

    2. B003P0TC02
      *1 Generator Drive End Frame
      *a Coil Lead

      Check the stator for a short circuit.


      1. Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Coil lead - Generator drive end frame Always 10 MΩ or higher

        If the result is not as specified, replace the generator assembly.

    3. Inspect the generator drive end frame bearing.


      1. Check that the generator drive end frame bearing is not rough or worn.

        If necessary, replace the generator assembly.

  4. INSPECT GENERATOR HOLDER WITH RECTIFIER


    1. B003LQVC02
      *a Terminal B
      *b Rectifier Terminal

      Check the positive terminal of the generator holder with rectifier.


      1. Using an ohmmeter, connect one tester probe to the terminal B and the other to each rectifier terminal.

      2. Reverse the polarity of the tester probes and repeat the step above.

      3. Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal B - one polarity Always Below 1 Ω
        Terminal B - other polarity Always 10 MΩ or higher

        If the result is not as specified, replace the generator holder with rectifier.

    2. B003QQXC02
      *a Negative (-) Terminal

      Check the negative (-) terminal of the generator holder with rectifier.


      1. Using an ohmmeter, connect one tester probe to the negative (-) terminal and the other to each rectifier terminal.

      2. Reverse the polarity of the tester probes and repeat the step above.

      3. Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Negative (-) terminal - one polarity Always Below 1 Ω
        Negative (-) terminal - other polarity Always 10 MΩ or higher

        If the result is not as specified, replace the generator holder with rectifier.

  5. INSPECT GENERATOR REGULATOR ASSEMBLY


    1. B003KMKC03
      *a Terminal F
      *b Terminal B

      Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      Terminal F - Terminal B Always Below 1 Ω or higher than 10 MΩ

      If the result is not as specified, replace the generator regulator assembly.

      Tech Tips

      When the ohmmeter leads are initially touched to the regulator, one of the above values is output.

      When the leads are reversed, the reading changes to the other value.

    2. B003JXPC03
      *a Terminal F
      *b Terminal E

      Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      Terminal F - Terminal E Always Below 1 Ω or higher than 10 MΩ

      If the result is not as specified, replace the generator regulator assembly.

      Tech Tips

      When the ohmmeter leads are initially touched to the regulator, one of the above values is output.

      When the leads are reversed, the reading changes to the other value.