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1. ss 24 22 16 1712615 2 i 10 mmm Ly i Hor i H INI i H T FH aH BH H 00 1600 2404 3200 4000 4600 5500 8400 7200 8000 GENERATOR R RM FIGURE 30 third brush generator and its connection to the circuit breaker are shown in Figure 31 This type of unit is restricted to applications requiring low output generators BATTERY TERPHUNAL INSULATED 2 TUN BRUSIE GROUNDED FIGURE 31 2 Third Brush Control with TC Regulator The two charge regulator was developed for use with the third brush generator so that its out put varied in accordance with the state of charge of the battery The two charge regulator is de signed to permit the generator to charge at its high rate until the voltage reaches a predeter mined maximum at which time the output js re duced approximately 50 The higher output is produced whenever the demands on the gener _ THIRD BRUSH D OUTPUT 14
2. Unit D E Contro o unces nit E ontrol o uncas gt GAR 4613 3 CW IC GAR 3 50 60 GAS 4152 CCW CB GASO 15 20 GAR 4613 4 CW GAR 4 50 60 GAS 4157 CW TC GAS 0 15 20 GAR 4614 4 CW GAR 4 50 60 GAS 4159 CW TC GAS 1 15 90 GAR 4614 CW 5 50 60 GAS 4160 CW CB GASO 15 20 i GAR 4616 CW GAR 3 50 60 GAS 4161 CW GAS 0 15 90 i GAR 4617 TC GAR 3 50 60 GAS 4162 CW CB GAS 0 15 90 i GAR 4618 CW 9 50 60 5 4163 GAS 0 15 90 i GAR 4619 GAR 3 50 60 GAS 4164 CW CB GAS 0 15 90 i GAR 4620 TC GAR 5 50 60 GAS 4165 TIC GAS 0 15 90 Cn ol S is GARS 5252 GAS 4166 CCW CB GAS 1 15 90 1 4 GAR 3 50 60 GREEN Y E GA cram me i GBE 4901 CW GBEO 5060 gt GAR 4625 CW IC GARS 50 60 GBE 4202 CCW CB GBE 0 50 50 i GAR 4626 CW 50 60 GBE 4903 CW CB GBE 0 50 60 GAR 4627 QGAR 3 50 60 GBE 4204 CCW CB GBE 0 50 60 GAR 4630 CW 50 60 GBE 4905 CW CB GBEO 50 60 i GAR 4631 cw TC GAR 5 50 00 GBE 4906 CCW CB 0 i GAR 4632 CW CB GAR 3 50 60 GBE 4907 CCW CB GBE 0 i GAR 4633 CB GAR 3 50 60 GBE 4908 Cy GB GBE 0 GAR 4634 CW GB GAR 2 50 60 4909 CCW TC GBE 0 GAR 4635 cw TC GAR 5 50 60 GBE 4301 CB GBE 0 GAR 4701 CW IC GAR 6 18 29 I GAR 4702 CW GARO 18 22 Gea an 1835 1 GBG 4603 CW CVR GBG 0 GAS 4102 1 CCW 5 1 15 20 BG 4606 CW CV
3. Y T APPROXIMATE OUTPUT TO FULLY CHARGED BATTERY AND WITH NO CONNECTED LOAD 400 800 200 1600 2000 2420 2800 3 00 3600 4000 4400 4800 GENERATOR RPM FIGURE 36 RAN INSULATED MAIN BRUSH GROUNDED MAIN BRUSH FIGURE 37 1 Wiring A visual inspection should be made of all wir ing to be sure that there are no broken wires and that all connections are clean and tight AUTO LITE ELECTRICAL EQUIPMENT GENERATORS Continued 2 Commutator if the commutator is dirty or discolored it can be cleaned by holding a piece of 00 sandpaper against it while running the armature slowly Blow the sand out of the generator after clean ing the commutator If the commutctor is rough or worn the generator should be removed from the vehicle the armature removed and the com mutator turned down See page 31 for instruc tions on this operation 3 Brushes The brushes should slide freely in their holders If the brushes are oil soaked or if they are worn to less than one half of their original length they should be replaced See page 32 for servicing instructions 4 Brush Spring Tension The brush spring tension shovld be checked If the tension is excessive the brushes and com mutator will wear very rapidly while if the ten sion is low arcing between the brushes and com mutator and reduced output will result
4. mmmn 3 S 26 AUTO LITE ELECTRICAL EQUIPMENT GENERATORS hinge type mounting while large trucks and sta tionary engines may use flange base or barrel type mounting Special mountings are often de signed to fit applications not adaptable to the standard hinge or flange types The type of drive also varies for different applications The generator is the source of all electrical energy on a car It supplies power for the ignition lights heater radio and other accessories The FIGURE 29 battery stores some of the generated energy in chemical form to be used when the generator is not running The battery is not a source of elec tricity but only a storage reservoir In starting for instance the battery supplies the energy but as soon as the engine starts the generator begins to replace the electricity taken from the battery Thus the generator must be of sufficient capacity to supply all of the current used on the cor D Anan uriy sd nii Aen doeet TRUE asi in 1 RN id aedis mente ne al M BERGE ABA TS mtra vier eN maad AAA AESA et aR e aea a Aa M SP AUTO LITE ELECTRICAL EQUIPMENT GENERATORS Continued Original equipment bateries are selected with sufficient capac
5. 4 i j 1 EM i AUTO LITE ELECTRICAL EQUIPMENT GENERATORS Continued e Cup oilers This type of oiler has a spring cover and is found at the side of the end plates The cups should be filled with medi um engine oil every 5000 miles When the generator is disassembled and cleaned ihe absorbent bronze bearings should be soaked in oil before assembling and the bail bearings should be packed one half full with a high melting point grease Care must be taken not to over lubricate any of the bearings as the surplus oil may deposit on the commutator or brushes allowing them to become oil soaked and seriously affect the operation of the generator 8 Generator Test After the generator is assembled and the brushes are properly fitted the generator should be bench tested under conditions of speed volt age amperes and temperature as near as pos sible the same as when in operation on the car before installing on the car See pages 34 to 39 for complete test data All generators should be polarized with the car battery before running This can be done by using a jumper from the starting switch battery terminal to the armature terminal of the gen erator AUTO LITE ELECTRICAL EQUIPMENT GENERATOR TEST DATA The following numerica
6. RELAYS AND REGULATORS Continued the generator and noting the maximum voltage reading when the generator is re started 3 Check current limiting regulator unit Connect the test ammeter in series between the regulator B terminal and the battery See Fig vre 84 By increasing the generator output with a lamp bank or other suitable resistance connected across the battery on the battery side of the am meter the ampere output should be as noted on the name plate of the regulator under test with an allowable variation of 575 Its gpetation is adjusted by varying the arm ature spring tension This is done by turning the screw c Figure 83 which holds the lower end of the spring It is necessary that after all adjustments are AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued NUMERICAL LIST OF VR TYPE REGULATORS See page 68 for test specifications Rated Test Ground Carbon Resistors Operating Part No Volts Spec Polarity RI R2 R3 R4 Amperage VRA 4101A 12 1 Positive 135 15 65 19 21 VRA 4102A 12 1 Positive 135 15 65 39 41 VRA 4103A 12 2 Positive 135 15 68 2 19 21 VRB 4002A s Positive 40 NE 29 31 4002 6 At Positive 60 2222 ndm t 24 26 VRB 4002D 6 4 Positive 60 Fou 27 29 VRB 4003A At Positive 30 ue uie x VRB 4004A 4T Positive 60 1 sel VRB 40
7. kes VRE4000D 0 ae XE DU XT VRE 4008 amp uve MS m ot eere 7400 0754 E VRE 4003A 1 if f EAR ae ELE E c VRE 4004A IR M ONE d E ERR VRE AOO5A kuis CNRC X Part No VRF 4001A gt VRF 4003A _ VRF 4007 VRG 4101A Rated Volts 12 12 12 12 12 AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued Test Ground Carbon Resistors Operating Spec Polarity RI R2 R3 R4 Amperage 9 Positive 802 Atte 02 XU 9 Positive 30 9 Positive dee Aine sities 9 Positive Z 30 5 M Zo 9 Positive 30 tae OM 9 Positive 580 2 Positive 1 Positive 1 Negative Positive Positive Negative Negative Positives Q Negative Positive Positive Positive Positive Positive Positive Positive Positive Positive Positive Positive Positive Positive Negative Positive Positive Positive Positive Positive lt Positive Positive Positive Negative Negative Port No VRP 4009B VRP 4009C VRP 4105A NRP 4201A 1 VRP 4009D _ OO O O ON O OO O OM O O O OO O o Ov O p N AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued Rated Test Volts Spec 12 lt Positive Ground Polarity Negative Negative Neg
8. ncaa ering Pss nuns te AUTO LITE ELECTRICAL EQUIPMENT STARTING MOTORS AND SWITCHES Continued To check this clearance shift the pinion by apply ing pressure to the yoke arm on the positive shift type or by applying pressure to the plunger of the solenoid switch on the magnetic gear shift type PINION HOUSING tacts closed by ehergizing the switch to approxi mate the actual conditions of operation TEST SPECIFICATIONS Amperes Draw 6 volt units 2 9 to 3 3 amperes at 6 volts 12 volt units 1 47 to 1 57 amperes at 12 volts Switch Contacts Close 6 volt units 4 to 5 volts 12 volt units 8 volts maximum 3 Switch Contacts Open ae 6 volt units 5 to 2 0 volts WASHER 12 volt units 1 5 to 4 0 volts A z SS 4100 SS 4200 and SS 4700 SWITCHES ex 5 n FIGURE 100 The relay contacts when open should have 025 inch minimum to 035 inch maximum gap 1 j 1 f i To adjust the clearance screw the starting switch plunger in or out on the positive shift starting motors or adjust the plunger screw on the mag netic shift starting motors STARTING SWITCH TESTS MANUAL SWITCHES This type of switch can best be tested by com paring voltage readings between the terminal connected to the battery and the terminal connected to the starting motor A maximum vari ation not in excess of 05 volts per 100 amperes is allowed greater variation
9. The upper right hand gauge is a retard type pressure gauge with a range of from 0 10 30 pounds per square inch can be used for checking either fuel pump pressure or exhaust back pressure The upper left hand gauge is a vacuum gauge with a range of 0 30 of vacuum This gauge is used to check intake manifold vacuum as well as checking the spark advance calibration of vacuum type distributors The lower gauge is a compression gauge It has a range of 0 150 pounds per square inch It is used for testing engine compression pressure Complete operating instructions are included in a booklet shipped with each instrument ST 265 CONDENSER TESTER This tester Figure 5 is a single meter instru ment designed to provide three tests for automo CONDENSER TESTER THE E upto ape LITE CO FIGURE 5 tive condensers leakage capacity in microfarads and 500 volt insulation breakdown test With it condensers can be tested either on or off the vehicle Shipped with each tester is an instruction book let which gives complete details as to its usage ST 270 UNIVERSAL HORN TEST BRACKET To properly adjust Auto Lite horns it is neces FIGURE sary that they be mounted on a properly de signed test bracket Figure 6 Do not hold any horn in a vise clamped by the horn flange as this may crack the diaphragm ST 272 HORN FEELER GAUGE SET These gauges illustrated in Figure 7 are for
10. brass side must be up Stripped or crossed threads on any screw or nut Corrosion due to sait or acids Evidence of water having been inside of cover Incorrect bent or distorted armature spring In case of doubt it is recommended that the spring be replaced Broken or altered carbon resistors Broken gaskets Incorrect wiring connections between units Shunt breaker armature must be free and not leads and terminal on circuit interfere with armature movement or touch tension spring See pages 65 to 70 for complete test data on VR type regulators CONTACTS The contacts should be cleaned by filing par allel with the length of the armature with a very fine file ST 290 recommended so that they are free from pits or burning After filing the contacts chloride to remove any dirt or grease Pull a clean piece of linen tape between the contacts to i remove any residue CARBON RESISTORS Check the resistance of the carbon resistors These resistors are found on the under side ofthe regulator base and should be removed and checked one at a time in order to avoid any inter changing Use an accurate ohmeter for checking the resistance CIRCUIT BREAKER 1 Check resistance of circuit breaker voltage winding B An accurate ohmeter is needed for this test This test is made by disconnecting the voltage winding ground connection and measuring from the lead to the stati
11. 0595 0625 15 nas 048 0527 AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued _ ARCUIT BREAKER Res of Voltage 222222 04 22 4 5 Armature Air Contact Point Gap eese Suq Aa ti t asas askai Points Close Volts nere ret treten Points Open AMDE DS VOLTAGE REGULATOR Res ot Winding cuu ala saa su Armature NC mm Contact Point Gop ciii rte acce Operating Voltage Lud ma EE Lal RM Tolerance cv k IRRENT REGULATOR 17 15 8 17 4 0595 0625 015 min 6 5 6 6 0 5 4 0 4 3 4 7 040 042 010 min 7 41 7 38 7 35 7 32 7 29 7 26 7 23 7 20 15 033 037 047 04 74 010 18 497 060 065 015 min 13 0 13 5 0 5 4 0 15 7 17 3 0465 0495 010 min 14 31 14 28 14 25 14 22 14 19 14 16 14 13 14 10 15 0465 0495 010 min V ins A TUM a et L devis u lcs i aat ctas ARD De UR er into eat AUTO LITE ELECTRICAL EQUIPMENT STARTING MOTORS AND SWITCHES DESCRIPTION AND FUNCTION The s
12. HO AMPERES D o 4 5 OUTPUT WITH Te ATOR OPERATI v o 800 1600 2400 3200 4000 4800 5600 8400 7200 8000 GENERATOR R P M FIGURE 32 ator are large while the lower output is pro duced when the battery is full and the connected load is small A typical charging curve of a third brush generator with a two charge regulator is shown in Figure 32 and the internal connections in Figure 33 70 BATTERY RESISTANCE FUSE THIRD BRUSH INSULATED MAIN BRUSH GROUNDED SIUM BRUSH FIGURE 33 pacity generator to be used without overcharging the battery The two charge regulator allows a larger ca AUTO LITE ELECTRICAL EQUIPMENT 4 z 1 GENERATORS Continued 3 Third Brush Control with VR Regulator When a vibrating type voltage regulator is used with a third brush generator ihe output con forms closely with the requirements of the battery and connected load The regulator holds the gen erated voltage constant under wide variations of loading Thus the charging rate varies to allow a high current when the battery is low or when a large load is being used if the battery is fully charged and there is no accessory load the regu lator holds the generator output to a low sus taining charge When high resistance connec tions develop the charging circuit the ou
13. These cycles occur at sufficiently high frequency so that the output is limited to a predetermined maximum CAR TEST ANY WORK IS DONE ON THE REGULATOR THE FOLLOWING CONDI TIONS SHOULD BE CAREFULLY CHECKED AND CORRECTED IF AT FAULT 1 WIRING FROM GENERATOR TO REGU LATOR PROPERLY CONNECTED 2 HIGH RESISTANCE CONNECTIONS IN THE CHARGING CIRCUIT THIS SHOULD BE CHECKED WITH AN ACCURATE READ ING VOLTMETER AND INSPECTED ME CHANICALLY FOR POORLY SOLDERED TERMINALS AND LOOSE OR CORRODED CONNECTIONS 3 GENERATOR PERFORMANCE WITHOUT THE REGULATOR IN THE CIRCUIT OPER ATING ACCORDING TO SPECIFICA TIONS 4 THAT THE REGULATOR IS THE ONE DE SIGNED FOR THE GENERATOR WITH WHICH IT IS OPERATING THESE REGU LATORS WILL FUNCTION SATISFACTOR ILY ONLY WHEN INSTALLED WITH THE GENERATOR DESIGNED TO OPERATE IT ALSO BATTERY CONDITION AFFECTS REGULATOR OPERATION AN OLD BAT TERY ONE PARTIALLY CHARGED OR ONE SUBJECTED TO EXCESSIVE HEAT WILL CAUSE HIGH CHARGING RATE WHILE ONE SUBJECTED TO EXCESSIVE COLD HARD PLATES HIGH RESISTANCE SEPARATORS AND SULPHATION WILL CAUSE LOW CHARGING RATE THE fies aes CIRCUIT TERMINAL VOLTAGE THE BATTERY AS WELL AS ITS SPECIFIC GRAVITY SHOULD BE CHECKED THE CONDITION OF THE BATTERY AS TO CAPACITY LEAKAGE ETC SHOULD BE CHECKED BY SEPARATE TEST AS SPECI FIED BY THE BATTERY MANUFACTURER The equipment needed for testing on the car in
14. CONNECTIONS 2 RESISTANCE OF CABLE CONNECTIONS BATTERY CAR FRAME I RESISTANCE OF GROUND CONNECTIONS Oe SWITCH o Jo 000 WATT 500 AMPERE CARBON PILE SHUNT FIGURE 95 switches the contacts should be closed electric ally to simulate actual conditions of operation DISASSEMBLY To remove the starting motor from the car dis connect the leads and cover the battery lead with a short piece of hose to prevent short cir cuiting Take out the flange bolts holding the motor to the flywheel housing The motor will then lift off and can be taken to the bench for a com plete overhaul When disassembling the motor each part should be removed and cleaned and inspected for wear or damage The Bendix drive or over running clutch should be cleaned and inspected for wear and for a distorted spring Bearings should be checked for proper clearance and fit All insulation should be free from oil and in good condition The armature field coils and brushes should be checked for grounds or open circuits 2 Brushes The brushes should slide or swing freely in their holders and make full contact on the com mutator Worn brushes should be replaced When replacing brushes that have the lead riveted to the brush holder the rivet should be removed and the new rivet should be securely staked to make sure the brush holder is solid and that the lead makes a
15. Check the pressure of the contacts To test disconnect the spiral spring from the armature and remove the adjustable armature stop Using a spring scale as shown in Figure 79 id holding the armature firm take a reading just as the contacts separate re assembling the armature stop be the current regulator yoke See Figure 81 sure that the fibre bumper block is in place See Figure 80 CURRENT LIMITING REGULATOR 8 Check the resistance of the frequency wind ing An accurate ohmeter ST 284 is needed for this test FIGURE 81 To test disconnect the lead from the current regulator unit where it is connected to the resistor through the sub base between the current and voltage regulators and measure from this lead to When re assembling the armature stop be sure that the fibre bumper block is in place See Figure 80 m 29 Check the pressure of the contacts gu BAYS ae AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued To test disconnect the spiral spring from the armature and remove the adjustable armature stop Using a spring scale as shown in Figure 79 and holding the armature firm fake a reading just as the contacts separate When re assembling the armature stop be sure that the fibre bumper block is in place See Figure 80 10 Check armature air gap with the contacts just breaking Test with pin gauge
16. See page 34 for test figures 5 Lubrication Add 5 to 10 drops of medium engine oil A good grade of S A E No 20 oil to the oilers Grease cups should be filled with a high melting point grease and periodically turned down one turn GENERATOR At periods of approximately 15 OVERHAUL should be thoroughly checked and the genera 000 miles the charging circuit tor removed from the vehicle and reconditioned 1 Wiring Be sure that all connections are clean and tight and that there are no broken wires To check connect an ammeter between the battery term inal of the circuit breaker or regulator and the lead removed from this terminal Run the engine at a speed equivalent to 20 M P H Adjust the current to 10 amperes by turning on the lights At this 10 ampere charging rate a voltage read ing should be taken with a 10 volt voltmeter be tween the following points See Figure 38 a BG to GG volts b BG to RG volts c RG to GG 0 volts d RA to GA 1 volts VOLTS AMPS OHMS FIGURE 38 tip Asa loda wirt it f i i i i AUTO LITE ELECTRICAL EQUIPMENT GENERATORS Continued sss sss e RB to BB 1 volts If readings higher than these are obtained the wiring should be checked for high resistance connections 2 Armature The armature should be visually inspected for mechanical defects If the commutator is rough or worn it should be turned down in a lathe After tu
17. as in Figure 98 If the current is too high check the bearing alignment and end play to make sure there is no binding or interference aac ipe cate n co kasushpaqa di d ca BORE Mate iio e FIR LM NEM AUTO LITE ELECTRICAL EQUIPMENT STARTING MOTORS AND SWITCHES Continued 500 AMP SHUNT 8 fe B WATT CARBON PILE BATTERY Using a spring scale and torque arm as shown in Figure 99 check the stall torque to see that the motor is producing its rated cranking power The stall torque will be the product of the spring scale reading and the length of the arm in feet the torque is not up to specifications check the seating of the brushes on the commutator and the internal connection of the motor for high resistance See page 81 for test data BAT TERY SPRING SCALE N PULL HERE FIGURE 99 VOLTMETER CONNECTIONS FIGURE 98 The Bendix or clutch should be checked for cor rect operation The Bendix pinion should be checked to see that it shifts when the motor is operated under no load The overrunning clutch should be inspected for proper clearance when in the free running position This clearance should be 5 64 1 64 between the outer edge of the pinion and the thrust washer next to the outer pinion housing bearing as shown in Figure 100 THE ELECTRIC AUTO CITE MUS
18. iom 14 39 490 5 74252 uj 1436 7 7 is 14 16 17 61 14 33 1443 760 14 30 3410 7 59 S M 047 049 0595 0625 01 0 min 010 020 ng 158174 U 35 39 gt 055 062 034 038 034 038 015 min 2018 min 015 eee 6 5202 5 4 0 30 2128242 0595 0625 0107 0207 198 7296 795 j e rs 43 777 27 93 220542292 77 89 22 hb sos c 0407 042 sis San 0107 min PCIE TE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Sontindeg P DS 9 22210 CIRCUIT BREAKER Res of Voltage Winding eere inue Armature Air d 11 23 49 7 034 038 060 065 Contact Point Gop 015 min 015 min Points Close Volts wee 13 0 13 75 13 0 13 5 Points Open Amps 5 3 0 5 4 0 Points Open Volis j zh VOLTAGE REGULATOR Res of Winding Armature Air Gap Contact Point Gap Operating elton SOR oa Raine 50 5 Rane E 59 42227 14 54 0595 0625 010 020 2714 50 14 46 14 42 _ 047 049 010 049 05 E 2 min 11 12 345 29 8 33 0 034 038 0317 034 015 min 015 25 0 25 75 5 2 0 is 191 209 0595 0625 010 020 27 84 27 67 27 50 2733 gt
19. opens the contacts disconnecting the generator a Th from the battery l MAINTENANCE PROCEDURE 1 Contacts The contacts can be cleaned by filing parallel with the length of the armature with a very fine file ST 290 recommended so that they are free from pits or burning After filing the contacts should be cleaned with refined carbon tetrachloride to remove any dirt or grease Pull a piece of clean linen tape between the contacts to remove any residue 2 Adjustments a Armature air gap 010 to 030 inches This gap is measured with the contacts closed VON AV TE RUN P ALN EEA II TET ALITTLE e E AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued and is adjusted by raising or lowering the sta tionary contact A Figure 43 b Contact gap 015 to 045 inches Adjustment is made by bending the armature stop B Figure 43 3 Testing and Adjusting a Contact closing voltage 6 volt units 6 5 to 7 25 volts 12 volt units 13 to 14 5 volts Adjustment is made by increasing or decreas ing the tension of the armature spring by bend ing the lower spring holder C Figure 43 b Contact opening amperage CB and RA types 6 volt units 5 to 2 5 amperes discharge 12 volt units 5 to 2 amperes discharge CBA type 6 volt units 1 5 to 4 5 am peres discharge TC TWO CHARGE RE
20. 1501470 GCX0 3944 202 410 2 3 70 4 10 80 17 0 19 0 GCY O 1 19 1 32 15 0 33 0 NES GAR 3 3 70 440 80 190 2106 GCY 3 1 19 1 39 20 0 GAR 4 3 75 4 15 80 99 4 94 4 GCZ 0 1 90 2 10 i GAR 5 3 51 3 89 8 0 90 4 994 GDA 0 1 66 1 84 i GAR 6 3 51 3 89 80 90 5 99 5 GDA 1 66 1 84 2202 GASO 3 80 4 20 80 13 3 15 3 GDB 9 3 29 3 58 15 i 90 6 6 7 6 GDC 0 1 3 1 6 16 0 18 0 GDE 0 380 490 80 EU 1403160 GDF 0 1 90 9 10 8 Dome 1 38 1 52 15 0 40 0 1065 GDF 1 1 90 2 10 78 8 0 9240 2060 GDF 2 1 90 9010 8 0 80 19 0 91 0 GDG 0 3 90 440 7 0 I 8 0 91 0 93 0 GDJ 0 1 48 1 64 15 0 1 8 0 15 5 17 5 GDM 1 1 41 1 56 15 0 4 20 80 19 0 91 0 GDO 1 1 10 1 30 8 0 490 80 17 0 19 0 1 45 1 65 15 0 4 20 80 10 0 19 0 1 65 1 82 80 4 4 90 80 140 16 0 1 65 1 82 80 4 90 8 0 8 0 10 0 1 58 1 79 80 E y 457 780 160180 35 39 8 0 E 457 80 950 970 87 971 30002 4 69 8 0 1 0 93 0 9 94 9 48 15 0 60 3 57 150 100 190 1 60 1 78 80 30 0 3 42521 3 57 150 9 6 10 6 1 57 1 75 80 350 3 89 780 97 47 1 57 1 75 80 3590 1 84 8 0 990 1800 1 60 1 78 8 0 39 0 i 1 84 80 14 0 1380 1 60 1 78 80 160 3 15 80 988 308 1 60 1 78 80 5 35 0 2 94 80 2900 990 gt 1 60 28 57 80 95 0 1 70 80 95 0 1095 1 60 1 78 8 0 39 0 43 1 59 715 0 90 0 1110 1 87 9 06 15 0 8 0 10 1 84 80 30 0 1500 9 95 9 8 80 130 154 3 9 4
21. 68 64 68 64 68 64 68 64 68 64 68 64 68 64 68 64 68 64 68 64 68 64 68 64 68 24 36 23 26 23 26 23 26 93 26 23 26 23 26 23 26 23 26 53 Max 53 Max 53 Max 53 Max 53 Max 53 Max 53 Max 53 Max 53 Max 53 Max 53 Max 53 Max 53 Max 53 Max 53 53 53 53 53 53 Max 53 53 Max 53 Max Vial acude deni ten RAED ERROR iae n issu gs son a Unit GCM 4805 GCM 4806 GCM 4807 GCM 4808 GCM 4809 GCM 4810 GCM 4811 GCM 4812 GCM 4814 GCM 4815 GCM 4816 GCM 4818 GCM 4890 GCM 48 1 4899 GCM 4894 GCM 4825 GCM 4827 GCO 4801 GCO 4803 GCO 4804 GCO 4806 GCO 4807 GCO 4808 GCP 4801 GCP 4802 GCR 4801 GCR 4802 GCR 4803 i GCR 4804 GCS 4802 GCS 4803 GCS 4804 GCS 4805 GCS 4806 GCS 4807 GCS 4808 GCS 4809 I GCS 4810 GCS 4811 665 4819 GCS 4813 i GCS 4814 565 4815 GCT 4801 GCT 4802 GCT 4803 GCT 4804 GCT 4805 GCT 4806 GCT 4807 GCT 4808 GCT 4810 GCW 4804 GCT 4811 GCW 4802 tThird brush spring tension should be 50 to 60 ounces CVR GCO 0 53 Max GDA 4809 CW CVR GDA 1 VR GCT 0 53Max GDG 4501 CW No GDG 0 VR 0 53 Max AUTO LITE ELECTRICAL EQUIPMENT GENERATORS Continued Spring E de Test Tension Rot MC Test r Control No Ounces Unit D E Control No scia TC GCM 4 53 Max GCW 4805
22. 99 CW TC GAE 0 20 96 GAR 4535 GAR O 18 99 CCW TC 0 90 96 GAR 4536 CCW CB GAR O 18 22 CB 0 90 26 GAR 4537 CB GAR O 18 22 CW TC GAE 0 90 96 GAR 4540 CB GAR O 18 22 4046 CCW 0 90 96 GAR 4541 CW CB GAR O 18 92 GAE 4047 CW TC GAE O 90 96 CUP od AR 1 dec 54133 CW 99 97 SAP 4 GAG 4145 CW 1 99 97 GAG 446 22 27 GAR 4546 CCW CB GAR 0 17 99 GAG 4148 CW 22 27 GAR 4548 CCW TC 17 29 GAG 4151 CCW CB 22 27 GAR 4551 CCW GAR O 18 92 GAL 4336 CW CB 0 17 22 GAR 4553 TC GAR O 18 22 GAL 4340 CCW CB GAL O 17 22 SA PE eU E AE t 4504 0 18 22 GAR4601 CW CB 5 50 60 GAM 4601 CW CB 0 18 99 AR 4603 cw CB e ARS 50 60 4133 CW CB 99 97 A 3 9997 GAR4605 CW CARA on GAP O 99 97 G arre ey Cpe se Ae 50 6 CV GAPO 92 97 EA ME 2072 CCW CB 99 97 G A c Te AU 200 CV 99 97 GAR 4609 4 50 ccw CB GAP 0 99 97 GAR 4610 CW TC GAR 4 50 60 GAR 4611 CW TC GAR5 50 60 17 99 GAR 4612 CW TC GAR3 50 60 VR Third brush and vibrating voltage regu msi Em ns PIS R e ga mi ta AUTO LITE ELECTRICAL EQUIPMENT 9 3 GENERATORS Continued Spring Spring ost gt Rot Tonton
23. This is to be measured on the contact side of the brass armature stop pin as shown in Figure 76 To test connect a C P light in series with the A and terminals and a battery as illustrated in Figure 77 With the low limit pin gauge in place depress the armature and the light should go out With the high limit pin gauge in place the light should stay lighted Use two fingers in de pressing the armature one on either side of the contact spring so that the contact spring is not touched The pressure should be applied near the center of ihe armature To adjust loosen the screws and raise or lower the armature stop Be sure these screws are tightened with suitable lock washers The spring upon which the movable contact is mounted should be ios d and with he armature 11 Check contact with the armature against the stop pin Figure 78 Hold ihe armature down with two fingers os illustrated Test figures shown for this gap are approxi mate only Too much variation indicates wrong connections that these connections are firmly charge It is for this reason that spring di which have flat spade type term als are r length to armature stop pin and a new unit will be needed RE ASSEMBLING THE REGULATOR When all the preceding checks and adjust ments have been completed all the leads which have been disconnected either by the removal of a screw or by unso
24. fit AUTO LITE ELECTRICAL EQUIPMENT GENERATORS Continued When assembling bearings or end heads that are equipped with oil wicks always remove the wick and replace it only after the armature and end heads are assembled Absorbent bronze bearings and wicks should be soaked in oil before assembling and the ball bearings should be packed one half full with a heat resisting grease before assembly 7 Lubrication Generator armatures may be mounted in ball bearings or in oil absorbent bronze bearings The drive end bearing is usually a ball bearing while the commutator end bearing may be either ball or absorbent bronze depending on the size and application of the generator Nearly all generators are provided with oilers at both ends These oilers are usually of the fol lowing types a Hinged top These are located over the bearing and should be given 5 to 10 drops of medium engine oil every 5000 miles b Swinging type this type is used only on the commutator end cap cover and should be filled full of medium engine oil every 5000 miles Cup and wick oilers This type is found _ under the bearing The cup should be re moved and filled with medium oil every 5000 miles d Grease cups These are usually located at the side of the end plates The cups should be given one turn every 5000 miles When refilling cups use a high melting point grease MESRINE ih Ans
25. indicates poor switch contacts Switch contacts should be filed for full surface contact or the complete switch replaced SS 4000 SERIES SWITCHES This type switch should be checked to see that the opening and closing voltages are within limits and that the voltage loss across the main contacts is not in excess of 05 volts per 100 amperes When checking this voltage loss have the con Before making any tests on the switch make sure that all linkage operates freely with no bind ing and that the switch plunger can be bottomed in the solenoid without drag or restriction When under test the plunger should bottom instantly without chattering TEST SPECIFICATIONS e ERR ci dB Ki ER Sele LS 55 4100 6 volt units Relay Contacts close 3 5 to 4 5 volts Contacts open 1 5 to 2 5 volts Solenoid Shunt coil only 14 to 16 amperes at 6 0 volts Shunt and series 34 to 38 amperes at 3 0 volts SS 4100 12 volt units Relay Contacts close 7 0 to 9 0 volts Contacts open 3 0 to 5 0 volts Solenoid Shunt coil only 5 0 to 6 0 amperes at 12 0 volts Shunt and series 22 0 to 26 0 amperes at 6 0 volts f AUTO LITE ELECTRICAL EQUIPMENT STARTING MOTORS AND SWITCHES Continued 5 4200 6 volt units SS 4700 6 volt units Relay Relay Contacts close 3 5 to 4 5 volts Contacts close 3 5 to 4 5 volts Contacts open 1 5 to 2 5 volts Contacts open 1 5 to 2 5 volts Solenoid Solenoid Shunt coil only 7 0 t
26. of the operation of the current limiting and voltage regulator units at the regulator by operating it for 15 min with the generator charging 10 amperes hile heating the regulator have the cover on the nit 1 Check circuit breaker operation Te test connect the ammeter in series between e battery and the B terminal The voltmeter onnected to the A terminal of the regulator fo ground Be sure that the voltmeter con ama Ei N ERTER FIGURE 82 AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued connections to avoid losses due to poor connec tions See Figure 82 To adjust the contact closing voltage adjust the armature spring tension by adjusting the screw Figure 83 which holds the lower end of the spring very accurate method of checking the contact closing voltage is by connecting a head phone 2000 ohms or higher between the A and B terminals of the regulator as shown in Figure 82 and observe the voltage at which the click caused by the closing of the contacts is heard To adjust the contact opening amperage adjust the contact gap by raising or lowering the stationary contacts After each adjustment replace the regulator cover and again test the circuit breaker oper ation There should always be 5 volts less voltage at AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND
27. place Then re check all adjust ments TESTING AND ADJUSTING NOTE THE COVER MUST ON THE RE LATOR WHEN TAKING READINGS OR WHEN THE UNIT IS BEING HEATED BY OPER ATION PRIOR TO TAKING READINGS THIS IS NECESSARY DUE TO THE FACT THAT THE COVER FORMS PART OF THE MAGNETIC FIELD AND ALSO HELPS TO RETAIN THE HEAT When testing or adjusting regulators care must be taken that it is mounted firmly and in a place where there is no vibration It must also be tested in the same position as it is mounted onthe car Care must be taken in making the various test connections that these connections are firmly made so that the resistance of all connections gt does not exceed 01 ohms 3 AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued HEAT THE REGULATOR BY OPERATING IT FOR 15 MINUTES WITH THE GENERATOR CHARGING 10 AMPERES WHILE HEATING HAVE THE COVER ON THE UNIT 1 Check circuit breaker operation First Method For circuit breakers having the upper contact mounted on a spring When making this test the voltmeter is connec ted between the A terminal of the regulator and a ground on the regulator base See Figure 67 To obtain the settings increase the voltage until the contacts close but the armature does seal to the yoke Take the contact closing voltage zat this stage Without increasing the vol
28. the armature The armature is then rotated slowly by hand If a shorted coil is present the steel strip will become magnetized and vibrate This test is illustrated Figure 97 5 Field Coils Using the test probes illustrated in Figure 96 check the field coils for both opens and grounds To test for grounds place one probe on the motor frame or pole piece and touch the other probe to the field coil terminals If a ground is present the lamp will light To test for open circuits place the probes on the field coil terminals across each coil separate ly If the light does not light the coil is open circuited 6 Brush Holder Inspection Using the test probes illustrated in Figure 96 touch the insulated brush holder with one probe and a convenient ground on the C E plate with the other probe If the lamp lights it indicates a grounded brush holder 7 Assembly of Motor When assembling absorbent bronze bearings always use the proper arbor as these arbors are designed to give the proper bearing fit Soak the bearing in oil before assembling in the bear ing bore The pinion end of the armature shaft should be given a light wipe with very light oil when assembling Brushes should be correctly installed and con nected as previously outlined in order to be sure of proper starting motor efficiency Proper brush seating should be insured by sanding the brushes to fit the commutator To sand the brushes wrap a strip of 00 sandpaper ar
29. 04B 6 AT Positive 30 7 7 uM VRB 4004C 6 4 Positive GO uu 2 22 a VRB 4005A 6 2 AT Positive VRB 4006A 6 2 4 Positive 30 VRB 4007A AT Negative 60 ommo 2D 4007 6 4 Negative 30 272 rere VRB 4008A 6 47 Positive 60 VRB 4008AP AT Positive 60 Hc VRB 4008B 6 4 Positive 60 1i VRB 4008C 4 Positive 30 Z SU VRB 4008D D 4 Positive 60 T1 uis VRB 4008E 4 Positive 60 1 ES VRB 4009A At Positive 60 CUm VRB 4010A 4 Positive 30 7 Su VRB 4011A 4 Negative 60 SMS VRB 4011B 6 4 Negative 30 VRB 4012A 6 4 Positive 30 VRB 4012A 1 4 Positive 30 VRB 4012B 1 4 E Positive 38 VRC4TOTA 55 5 Positive 80 E 5 7 Positive 80 6 5 Positive 80 6 5 e Positive 80 6 c At Positive 20 m U 6 A Positive 20 Goethe 6 4 Positive 20 as Positive 20 cc 6 Positive M 6 s Positive 20 Tm o6 24 22 Negative 90 5 Positive o DO nah po Mee 6 4 Positive ee IT 6 Positive 7 20 ee oes 6 Positive 830 D iu 6 i Positive E 20 x6 2 4 Positive 20 A seris 12 Positive 60 VRE 4001B Positive 44 n OMEN lt VRE 4001C Positive NE Ro VOL ue VRE 4002A EE amp Positive E luis VRE 4002B WX Positive Ev den ORAE VRE 4002C yi Positive
30. 1 1 1 7 5 1 85 5 TC 4320B 6 1 1 85 75 aw 6 5 5 5 TC 4321A 12 2 2 85 5 4305 6 2 85 5 TC 4322AT 12 2 1 85 5 TC 4305F 1 1 85 5 TC 4323A 6 7 20 5 TC 4306A 6 1 1 85 5 4323 6 7 7 5 TC 4307AT 6 4 1 85 5 TC 4324A 6 2 85 5 4308 4 6 1 1 85 5 coda arked volue with e 1C 4309A 6 1 185 5 the marked al with a tole nce of 5 1 TEST E TC REGULATOR TEST DATA Sas CIRCUIT BREAKER 1 2 23 Resistance of Voltage Winding 35 39 111 123 Vo 111 123 e Armature Air 010 030 010 030 7o 010 030 Contact Point 015 045 015 045 015 045 p Point Closing Volts 6 5 7 25 13 0 14 5 13 0 13 5 Point Opening Amps Discharge 2 2 2 5 2 0 520 VOLTAGE REGULATOR e i Resistance of Winding 29 33 102 112 ic zt Armature Air 044 046 044 046 044 046 Contact Point Gap 005 min 005 min 005 min to Low Charge 17 30 15 95 17 12 15 80 s 17 00 15 65 16 86 15 50 16 70 2010 1535 16 56 15 20 16 42 15 05 25 40 20 1 2 to 1 4 2 4 to 2 8 2 0 2 4 5 Volts below high to low Volts below high to low Volts below high to low Volts below high to low TEST 1 i De CIRCUIT BREAKER G 5 6 2 7 Resistance
31. 3 Max 41 52 41 52 41 52 64 68 64 68 64 68 64 68 64 68 64 68 64 68 64 68 64 68 64 68 64 68 64 68 64 68 Unit GCB 4815 GCB 4816 GCB 4817 GCB 4818 GCB 4820 GCB 4821 GCD 4801 GCD 4803 GCD 4804 GCD 4805 GCD 4806 GCD 4807 GCE 4803 GCE 4804 GCE 4806 GCE 4807 GCE 4808 GCE 4809 GCE 4810 GCE 4812 GCE 4813 GCE 4814 GCE 4815 GCE 4816 GCE 4817 GCE 4822 GCG 4601 GCH 4601 GCH 4602 GCH 4603 GCH 4604 GCH 4606 GCH 4607 GCH 4608 GCH 4609 GCJ 4801 GCJ 4802 GCJ 4803 GCJ 4804 GCJ 4805 GCJ 4807 GCJ 4808 GCJ 4810 GCJ 4811 GCJ 4812 GCJ 4813 4814 GCJ 4815 gt GCJs4816 GCK 4801 GCK 4802 GCK 4804 GCK 4805 GCK 4806 GCK 4807 GCM 4802 GCM 4803 GCM 4804 Rot D E Control CW CW CY CVR cw CW CW CVR CW cw cw CCW CVR CW CVR cw CW CW CVR CW CVR CW CW cw CVR CW CVR CW CW CVR CW CW CCW No CW CW CVR CW CW CVR CW CVR cw CVR CW CW CVR CW VR CW VR CW VR CB VR CW VR CW VR CW VR CW CCW CCW CB CW CB cy CB CCW Cw CVR CW COW CW CVR CVR CVR cw IC CW cw TC GCE 0 Spring Tension Ounces 64 68 64 68 64 68 64 68 64 68 64 68 55 65 55 65 55 65 55 65 55 65 55 65 64 68 64
32. 620 CW GBM 1 50 60 GAS 4145 CW TC 0 15 50 GBM 4800 CCW CB 5 37 44 GAS 4148 CW 54 15 50 GBM 4800 CW 5 31 441 GAS 4149 CCW TC GASA 15 20 GBM 4803 CW GBM 37 44 GAS 4150 GAS 1 15 90 GBM 4804 CW CB GBM 5 4 GAS 4151 GB GAS 1 15 20 GBM 4805 o GBM 5 2 tThird brush spring tension should be 50 to 60 ounces Unit GBM 4806 GBM 4807 GBM 4808 GBM 4809 GBM 4810 GBR 4501 GBR 4502 GBR 4601 GBR 4602 GBR 4603 GBR 4604 GBR 4605 GBR 4607 GBR 4608 2 QGBR 4609 GBR 4611 GBR 461 GBS 4501 904 GBU 4213 GBU 4214 GBU 4216 BW 4609 BW 4802 4803 4804 GBW 4807 GBW 4808 GBX 4601 GBX 4602 GBY 4601 GBY 4801 GBY 4802 GCB 4601 GCB 4802 GCB 4803 GCB 4804 GCB 4805 GCB 4806 GCB 4809 GCB 4810 GCB 4811 BU 421 7 GCB 4808 AUTO LITE ELECTRICAL EQUIPMENT Control GENERATORS Continued Test No GBM 4 GBM 1 GBM 6 GBM 5 GBM 1 GBR 3 Spring Tension Ounces 37 441 37 441 37 441 37 441 37 441 18 99 18 929 50 60 50 60 50 60 50 60 50 60 50 60 50 60 50 60 50 60 50 60 18 22 18 22 50 60 50 60 50 60 50 60 50 60 50 60 50 60 50 60 50 60 50 60 50 60 50 60 50 60 50 60 50 60 50 60 53 Max 53 Max 53 Max 53 Max 53 Max 53 Max 5
33. 8 0 30 0 4010 1 40 1 58 15 0 18 0 i 1 29 80 40 0 975 1 60 1 78 80 400 1 29 8 0 50 0 1025 1 60 1 78 8 0 90 0 9 1 5 80 240 960 1 38 1 53 150 07470 2 1 80 17 0 19 0 1 38 1 53 150 U 100 9 1 80 99 0 39 0 1 65 1 82 80 160 994 8 0 170490 9 65 9 99 15 0 0 93 1 65 15 0 19 0 1500 1 65 4 82 8 0 0 90 E 1 65 450 80 1975 1 65 1 82 8 0 21 153 89 80 150 170 2 1 60 1 78 1 58 0 a 3 89 180 910930 125 80 7 1 63 80 98 0 1850 06 9 99 14 9 1 70 1 90 8 0 19 0 1975 60 1 78 8 0 AT 1 63 15 0 15 0 1565 65 1 89 8 0 4 3 Ft Lbs at 5 0 Vols and 165 Amps Tt Lbs af 115 Amps ond 10 0 Volts DESCRIPTION The function of a circuit AND FUNCTION breaker automotive elec trical equipment is to automatically open and close the circuit between the generator and the storage battery It consists of an electromagnet and a set of contacts The electromagnet has two windings ne the shunt coil connected across the generator O GENERATOR TERMINAL FIGURE 42 lt When the generator is charging the battery e urrent is flowing through both windings in same direction When the current flows from to the generator the current is flow ing through the shunt coil in one direction and through the series coil in the opposite direction The circuit breaker co
34. 95 CW 0 64 68 GEO 4803 CW CVR 64 68 GEO 4804 CW CVR 0 64 68 GEO 4805 CW CVR GEB 0 64 68 GEO 4806 CW CVR GEB O 64 68 GEO 4807 CW CVR 0 64 68 4808 QM 52 0 64 OY eee 522 oe GEB 64 6 ER 4801 CCW CVR GEB O 64 68 i G S SES MA Creo x C GEB 1 64 68 CVR GEB 0 64 68 NN CW CVR 0 64 68 GEW 4801 CCW CVR GEB O 64 68 GEW 4802 GEW 4803 AUTO LITE ELECTRICAL EQUIPMENT GENERATORS Continued Spring Spring i Ret Test Tension Ret Test Tension i Unit DE Control No Ounces Unit DE Control Mo Ounces GEW 4804 GEW 0 64 68 GFA 4802 GFA 2 53 Max i GEW 4805 CCW CVR GEW 0 64 68 GFA 4803 CW CB GFA 2 53 j GEX 48014 CCW CVR GEX 0 64 68 GFA 4804 EB GFA 2 53 Max GFA 4801 GFA 9 53Max GFA 4805 GFA 2 53 Field Curreat uu Field Current i Test at 6 0 Volts Cold Ovtput Mox Test at 6 0 Valts Cold Output Max i No Amperes Volts Amps R P M No imperes Volts Amps R P M GAE 0 1 9 21 15 0 10 5 19 5 GCS 1 3 56 3 94 80 130450 i 0 4 08 4 52 80 150 170 2 5 5 3356 3394 80 19 0 2910 GAL 0 3 51 3 89 80 16 0180 GCLO j140 1 600 150 120430 GAM 0 3 89 4 31 80 15 5 17 5 GOT 140440 15 0 8090 22 GAR 0 3 51 3 89 80
35. Brush Holders With the test probes check the insulated brush holder to be sure it is not grounded Touch the insulated brush holder with one probe and a convenient ground on the C E Plate with the other probe If the lamp lights it indicates grounded brush holder n a Inspect the brush holders for distortion and improper alignment The brushes should swing or slide freely and should be perfectly in line with the commutator segments 5 Brushes Brushes that have been subjected to oil or are worn to one half or less of their original lengih should be replaced When replacing brushes it is necessary to seat them so that they have 100 surface contacting on the commutator The brushes should be sanded to obtain this fit This can be done by drawing a piece of 00 sandpaper between the commutator and brush and against the brush holder as illustrated in Figure 41 Do not sand SANDPAPER PULLED AGAINST BRUSH HOLDER FIGURE 41 ioo much as it merely shortens brush life After sanding the brushes blow the sand and carbon dust out of the generator The generator should then be run under load long enough to secure a perfect brush fit Generators are not to be tested for output until after the brushes are seated 6 Assembly of Generator oe When assembling absorbent bronze bearings d always use the proper arbor as these arbors are lesigned to give the proper bearing
36. CVR 3CW CCW CV Sewn 648 CB 53Max GCX4500 CB GCXO CB GCM 4 53 GCX 4502 CW CB GCX 0 740 TC GCM 4 53 60 453 CW CB 60 0 CB GCM 4 53 Max GCY 4601 CW GCY 0 CB 0 153 Max GCY 4603 CCW CVR GCY 1 CER CB 153 Max 7 60 4604 CVR 23 26 GCM 4 53 Max GCZ 4803 CCW CB GCZ 0 53 Max CB GCM 0 153 Max GCZ 4805 CCW CB GCZ 0 53 Max CB GCM O 153 Max GCZ 4806 CW CB GCZ 0 53 Max CB GCM 0 153 Max GCZ 4807 GCZ 0 53 Max TC GCM 4 53 Max GDA 4801 CW CVR GDA 0 53 d Hur DV Rd EDAD Mee 53 TC GCM 0 153 GDA 4804 CW CVR 53 ed CVR GCO 0 53 Max GDA 4805 CW CYR GDA O CVR GCO 0 53 Max GDA 4806 CW CVR GDA 0 CVR GCO 0 53 Max GDA 4807 CCW CVR GDA O Spring CVR 0 53 Max GDA 4810 CW CVR GDA 1 CVR GCO 0 53 Max GDB 4802 cow cB GDB 2 453 M CVR GCP 0 53 Max 4803 2 CVR 53 Mas 6084804 1 0050 CVR GCR0 53 GDB4810 CCW TC CVR GCR 0 53 GDB 4819 CCW IC GDB 0 CVR GCR O 53 GDB 4813 CCW TC GDB 9 53 4814 CW TC GDBo 153 ic 53 Me x GDC 4601 CCW No GDC 0 o 9655 3 lt GDEA40 CW TC GDEO TC GCS 5 53 Max GDE 4109 TC GDE o TC 5 53 GDE 4103 TC GDE 0 CB GCS 1 53 Max GDE 4104 CC
37. Do not polarize the generator by holding the circuit breaker contacts closed Use a jumper from the starting switch bat tery connection to the A terminal of the gener ator The excessive current in closing the circvit breaker contact for this purpose may result in burnt contacts VRA VRC VRG VRH AND VRY REGULATORS MAINTENANCE PROCEDURE VISUAL INSPECTION Before making any tests or adjustments it is recommended that a close visual inspection be given the regulator with special emphasis being paid to the following points 1 Broken regulator seal 2 Evidence of burning or abnormal high temperature at the coils contacts insula tion external terminals or any other point It is suggested that this test be made with a magnifying glass 3 Loose connections which result from poor soldering 10 11 12 13 14 15 16 17 18 AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued should be cleaned with refined carbon tetra Loose nuts on the bottom of the magnet cores loose rivets or screws All nuts and screws must have lock washers Loose contacts Misalignment of contacts Bent armature either at the contact or hinge end The armature should be per fecily straight from one end to the other Magnet yoke bent Bent armature hinges Reversed bimetal hinges on the circuit breaker unit When correctly installed _
38. E Figure 47 the unit being tested and at the temperature TESTING AND ADJUSTING shown Adjust by varying the tension of spring 1 Circuit Breaker Operation G Figure 47 by bending the spring hanger H Connect a voltmeter as shown in Figure 48 In a Reduce the voltage and check the contact crease the voltage from zero and note the volt 45 closing voltage as indicated by the lamp light ing This voltage should be within the test ficotions shown _ Adjust by turning the brass Figure 47 changes the contact gap dius by ERA which must not be less than 005 inch after i completed STR ure HI foad N aes E i LIGHT 3CP 6 8V eV BATTERY FIGURE 49 44 AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATQRS Continued TC REGULATOR NUMERICAL INDEX Rated Test X Rated Test Part No Volis No Resistor Fuse Part No Volis Na Resistor Fuse TC 4301A 1 1 4 5 TC 4310A 12 2 2 85 5 _TC 4301B 6 1 1 4 5 43108 12 2 1 85 5 4302 6 1 1 85 5 TC 4311A 6 1 1 85 5 TC 43028 1 1 1 5 TC 4312A 1 1 85 5 TC 4303A 12 2 2 85 5 TC 4313A 6 1 1 85 5 TC 4303B 12 2 2 85 5 TC 4314A 1 1 85 7 5 TC 4303C 12 2 1 85 5 TC 4315A 12 2 2 85 7 5 TC 4303D 12 3 4 5 4316 6 1 1 85 5 TC 4304A 4 1 85 5 TC 4317A 1 185 4305 6 1 1 85 5 4318 12 2 185 5 i 6 5 1 85 5 TC 4320A 6
39. GULATORS DESCRIPTION TC 4300 series regula AND FUNCTION tors are built both as a com bination circuit breaker and regulator and as a regulator only When the unit is a regulator only it is used in conjunction with a separately mounted circuit breaker The operation of the regulator unit is identical in both types ture changes a magnetic by pass is used i 12 volt units 5 to 3 5 am peres discharge Adjustment for contact opening amperes is made by bending the armature stop B Figure 43 This changes the gap of the contacts when open The contact gap contacts open must not be less than 015 inches after adjustments are completed FIGURE 43 Figure 44 shows the internal wiring connec tions of a combination circuit breaker and TC regulator The operation of the circuit breaker is the same as previously described on page 40 The TC two charge regulators operate on the principle of inserting a resistance in the gener ator field circuit when the generator voltage reaches a pre determined value and cutting out the resistance as the voltage falls below a sec ond pre determined value To meet battery characteristic changes resulting from tempera The magnetic by pass type of compensation operates by varying the amount of magnetic pull exerted on the armature at any given voltage according to the temperature The magnetic by pass is a small piece of
40. MAINTENANCE and OPERATION AUTO LITE ELECTRICAL EQUIPMENT PRIcE 1 OO Issued by The Electric Auto Lite Company Parts and Service Division Toledo Ohio U S A PRINTED IN THE UNITED STATES OF AMERICA E C M 5 t f i a hy i TABLE OF CONTENTS wt i Paga S SE N a Page DISTRIBUTORS Relays and Regulators Cont d i K Description and Ge VRB VRD VRJ a Governor Control Data 21 VRR VRS VRU VRV VRW and VRX i I Numerical Index Regulators E pus Synchronizing 2 2 22 15 Par fau UE nasi merus i Tune up Procedure 12 c Description and Function i 4 Vacuum Advance 25 Metatenance Procedure o p s E Numerical Index sess ET GENERATORS Testing and Adjusting TNT Description 26 Test Specifications j Maintenance 29 x EIN 2 Numerical Index 34 VRA VRC VRG VRH VRY Regulators z 2 I ELO Overhaul Procedure 30 Test j Test Specifications ru 39 Description ard Function 4 Maintenance Procedure Numerical Index Testing and Adjust
41. R This meter Figure 11 is a self contained unit 4 TE 2 1 ESISTANCE ORMS FIGURE 11 used to check the resistance of automotive elec trical windings Instructions for its correct usage are attached to each meter There are two scale ranges 0 6 ohms with graduations beginning with 01 6 600 ohms The generator is a device for changing mechan ical energy into electrical energy Generators are built in many voltages and design to fit the special requirements of the application for which they are intended Some generators are com pletely sealed to exclude moisture or dust Others are ventilated by a suction fan usually combined with the drive pulley A typical ventilated gen erator is illustrated in Figure 29 The air stream to AN NNNNNNNNSNNSUPHLEINNNN BEI od rte 12 ha a it u passing over the armature and field coils carries away the excess heat and allows a much higher output without the danger of burning out the armature or fields Ventilated generators are used on most automotive and truck applications while non ventilated generators are used on ma rine or tractor applications where dust or water di likely to cause damage T Most passenger cars and light trucks use a I Pd Pine SII ae Ay SS rr yr aa
42. R GBGO GAS M409A CCW CB GASA 15 90 ORG 4806 ov C GB 2 GAS 41098 CCW CB 1 15 20 46 ea i i 3 4608 CVR GBG 0 GAS 41090 CCW GAS 0 15 20 GBG 4509 CW CVR GBGO GAS 4103 CW GAS 15 20 46 GAS 4104 CW CB 50 15 20 CU p S S 22 i 41 0 15 20 I GAS 41048 CW CB 6450 15 20 GBJ 4601 CW GBI O S GAS 4106 CW GB GAS 0 15 90 GBK 4601 cw CB GBK 9 cow CB GASO 15 20 GBK 4602 CW GBK 41 9 5 Gd Se CCW CB 15 20 a i CB 5 0 15 20 4601 CW GBM 0 i CW GB 5 0 15 90 4609 CW 0 i CW GAS 1 15 90 GBM 4603 CW CB GBM 1 i GAS 4120A CW 5 0 15 90 4604 OW CB GBM 1 i GAS 4124 GAS 1 15 20 GBM 4606 CW GBM 1 GAS 4125 GAS 0 15 90 GBM 4607 CW GBM 1 i GAS 4195 1 CW GASA 15 20 4608 CW CB 0 i GAS 41 26 CB GAS 0 15 20 GBM 4608C CW CB GBM 1 i GAS 41 28 CW CB GAS 0 15 90 GBM 4609 CB GBM 0 3 GAS 4129 CW 50 15 20 GBM 4610 CW GBM 5 GAS 4131 CW GAS 1 15 90 GBM 461 1 CW CB 4 GAS 4132 CCW GAS 0 15 90 GBM 4612 CW CB 0 50 60 GAS 4136 CW IC GASA 15 20 GBM 4613 CW CB 4 50 60 GAS 4139 CB GAS 0 15 20 GBM 4616 CW TC GBM 1 50 60 GAS 4140 CB GAS 0 15 90 4617 CW CB GBM 5 75060 GAS 4141 CW CB GAS 0 15 90 GBM 4619 CCW CB GBM 5 50 60 GAS 4144 cw GAS 0 15 90 GBM 4
43. REGULATORS Continued VOLTAGE REGUL ATOR CIRCUIT BREAKER TI a a gt gt A aa aes q 55 m S ERR v e EN NI ah hs ot v a rem M NA U LN MIS A SS b 24 s ED PANE is el E 9 L ad l h A NE i A ALS x A 24 Z wr ES S gy lt gt gt lt 505 lt 25752522250 UN EXER ee SOI aa 77 ASA SS b CURRENT LIMITING REGULATOR FIGURE 83 THE mrerac TALI ee muaa SAMT and re Map En orina f FIGURE 84 Which the circuit breaker closes than the voltage at which the voltage regulator operates At the conclusion of this check it is necessary that a final flash test be made 2 Check voltage regulator unit In making this test an accurate voltmeter must used It is to be connected to the regulator B terminal and to ground See Figure 84 o adjust its operation increase or decrease rn ature spring tension Increasing the spring inet ses the voltage at which the unit will Operate while decreasing the tension de made a final flash test be made on all three units AUTO LITE EL BC TAICAT
44. S 0 53 Max GEE 4502 CW CB GEEO 7 10 CW VR GDS 0 53 Max GEF 4801 CW GEF 0 53 Max CW CB GDS4 53Max 4809 CCW CVR 0 53 Max 1 CW CVR GDT 0 55 65 4801 gt CW GEG 0 64 68 1 CW CVR GDT o 55 65 GEG 4802 CW GEG 0 64 68 CW GDT 0 55 65 ee Mi ee gis E 4805 1 64 6 GDUO GEG 4806 CW 6 0 64 68 i Ww GDW 0 93 96 GEG 4807 CW CVR 0 64 68 E GDW 0 93 96 GEG 4809 CW GEG O 64 68 3 GEG 4810 CW GEG 0 64 68 j GDY 0 15 90 4811 CW CVR GEG O 64 68 i G 4813 X 0 64 68 3 20 33M GiGasia CCW GEGO 6468 i 6070 53Max GEG 4815 CCW CVR GEG 1 64 68 6070 53 Max GEG 4816 CCW CVR GEG 1 64 68 23 GDZO EG 4817 CW CVR 84 68 i GDZ 0 53 Max GEG 4818 CW CVR 0 64 68 352 VE 45 GEG 4819 CVR GEG 7 64 68 9020 53 GEG4B20 CVR GEG 1 6468 GEG 4891 CW CVR GEG 0 64 68 u dX 53 Me GEG 4822 CW CVR GEG 0 64 68 3 5 x CVR CEAO 52 GEH 4802 CW GEH 0 64 68 4 CVR GEA 0 53 Max 4803 CCW CVR GEH 1 64 68 1 GEH 4804 CW CVR GEH 1 64 68 GEB O 64 68 GEH 4805 CW CVR GEH 0 64 68 CW 64 68 GEH 4806 CW CVR 0 64 68 CW 9 64 68 A 0 764 68 CW CVR 64 68 1 CW CVR GEBS O 64 68 GEO 4801 4 CW CVR GER 64 68 GEO 480
45. W TC lt BNMe GbE40s CCW 16 GbEO TC GCS 5 53 Max DF 4801 C ic Me DEAD TC GCS 5 53 Max GDF 4803 IC 9655 53 GDF 4804 CW VR TC GCS 5 53 Max GDF 4805 CCW CB TC GCS 5 53 Max GDF 4806 GDF 4807 CW CB GCT 1 53 GPF 4808 VR GCT 0 53 Max GDF 4819 cw VR CB GCT 1 53 Max GDF 4813 cw CB VR GCT O 53 GDF 4814 CCW VR GCLO 53 Max VR GCG SCO dl CEN NR CB GCI 53Max GD4 4801 B GCL1 53 Max D 53 Max 01 4803 GDJ 4804 CVR GCW 0 64 68 GDJ 4805 CVR GCW 0 64 68 GD4J 4806 Unit GDM 4803 GDM 4804 GDM 4806 GDO 4601 GDP 4801 GDP 4802 GDP 4803 GDP 4809 GDS 4801 GD5 4809 GDS 4803 AUTO LITE ELECTRICAL EQUIPMENT GENERATORS Continued Spring E I Spring Rot Test Tension Rot Test Tension D E Contrel No Ounces Unit D E Control No Ounces CW CVR GDM 1 55 65 4895 CW CVR GEB 0 64 68 CW GDM 1 55 65 4896 CW 3 64 68 E CCW CVR GDM 1 55 65 wn eU CER 64 68 ae 4898 0 64 68 CW CYR GDO 23 96 GEB 4899 CW CVR GEB 0 64 68 CW GDPO 5 Max i CVR 5 GEC 4801 CW VR GEC 53 CVR GDP 0 53 Max GED 4501 CW CB GED 0 7 10 CW CVR GDP 0 53 GEE 4501 CW CB GEE 0 7 10 3 cw VR GD
46. ading just as the dick caused by the closing of the contacis is heard See Figure 67 69 and 70 _ To adjust the opening voltage or amperage adjust the contoct gap by raising or lowering the stationary contact There must always be 5 volts less voltage at which the circuit breaker closes than the voltage at which the voltage regulator operates After each adjustment replace the regulator cover and again fest the circuit breaker action 2 Check voltage regulator unit In making this test an accurate voltmeter must be used It is to be connected to the regulator B terminal and to the regulator base as shown in Figure 71 To adjust its operation increase or decrease the armature spring tension by bending the lower spring arm with ST 283 See Figures 69 and 70 Replace the cover after each adjustment Take a flash reading by stopping the generator and noting the maximum voltage reading when the generator is re started at approximately 10 am VOLTAGE REGULATOR UNIT LOWER SPRING BRACKET BEND DOWN TO INCREASE VOLTAGE SETTING BEND UP TO DECREASE VOLTAGE SETTING MEC CIRCUIT BREAKER 7 UNIT LOWER SPRING BRACKET BEND DOWN TO INCREASE CLOSING VOLTAGE BEND UP TO DECREASE CLOSING VOLTAGE FIGURE 70 AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued BATTERY FIGURE 71 peres output with voltage regulator operating 3 he
47. ape between the contacts to remove any residue 3 Carbon Resistor Check the resistance of the carbon resistor with an ST 284 ohmeter The resistance must be ac POTENTIOMETER 3 AMP 100 OHM UPON UA EXTERNA wn cording to the values given in the test specifica tions at the end of this section 4 Circuit Breaker Unit a Armature Air Gap 010 to 030 inches This gap is measured with the contacts closed and is adjusted by raising or lowering the sta tionary contact A Figure 47 i b Contact Gap 015 to 045 inches Adjusted by bending the armature stop Figure 47 Dis me co AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued 5 TC Regulator Unit spring by bending the lower spring holder F a Armature Air Gap 045 001 inches Figure 47 This gap is measured with the regulator orcon 2 Regulator Operation tacts closed It can be adjusted by raising or low Connect a voltmeter as shown in Figure 49 ering the upper contact C by expanding oF Increase the voltage from zero and note the volt contracting the bridge D holding the upper age at which the contacts open as indicated by a contact the lamp dimming or going ovut This voltage b Contact Gap 005 inch minimum figure should be within the test specifications for Adjust by ne rning the brass cam
48. arm is taken up by the spring When the switch contacts close the armature rotates allowing the spring to SHIFT COLLAR FIGURE 88 asss AUTO LITE ELECTRICAL EQUIPMENT STARTING MOTORS AND SWITCHES Continued complete the meshing action and crank the en ne As soon as the engine starts the flywheel drives the pinion faster than the starting motor armature bringing the clutch into action and pre venting the engine from driving the armature at excessive speeds The Bendix drive is illustrated in Figure 89 It DRIVING HEAD HEAD SPRING BOLT OR SCREW Sel V CALLED FOR FIGURE 89 consists of a threaded sleeve fastened to the ar mature shaft through a drive spring and a pinion mounted on the threads of the sleeve When the starting circuit is closed the armature revolves n f rning the sleeve within the pinion forcing the gear forward meshing it with the flywheel gear The sudden shock of meshing is absorbed by the spring When the engine starts the pinion is driv en faster than the sleeve and is forced back along the threads automatically de meshing it from the flywheel STARTING SWITCHES Starting switches which control the closing and opening of the circuit between the storage bat tery and the motor may be of either the manual or solenoid type Manual type starting switches may be one of four types The type illustrated in Figure 90 is used w
49. ative Positive Positive Positive Positive Negative Negative Positive Positive Positive Positive Positive Positive Positive Positive ce Positive Carbon Resistors TEN Operating R2 R3 R4 Amperage 30 rA 27 29 60 158 2 39 41 30 rapa Wis 3 24 26 60 15 MES 31 33 30 uu c E 21 23 305 ea vere 7721 23 60 Non 19 21 6800 Pen 19 21 60 30 E 19 21 60 30 19 21 38 7 7 EE Lg 34 36 38 seen AE 30 AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued Se VR REGULATOR TEST SPECIFICATIONS TESTO bo gua vim CIRCUIT BREAKER a wo f Res of Voltage Winding 49 7 497 35 39 35 39 f 6 e Armature Air Gapt 4055 062 055 062 034 038 034 038 MR Contact Point Gap 015 min 015 min 015 min 015 min _ Points Close Volts es 0 13 0 13 5 13 0 13 5 7647 0 22 64270 Points Open Amps 5 4 0 5 4 0 5 3 0 5 30 COMER OE 157 173 157 73 128 143 104 112 m 22 0407 0420 040 042 0595 0625 05957 0625 TANE s 0107 min O10 min 107 020 0107 0209 US ore gt oum dS 68 7 51 14 48 14 28 7 66 2 7 48 14 45 22214250000 2 65 15 TAB 14 42 5142292 C 0 2
50. ature is depressed Use two fingers see Figure 64 to depress the armature being careful not to touch the contact spring FIGURE 64 3 C P LAMP that it is approximately parallel with the arm ature Re install the spiral spring being sure that the correct spring is used and that both ends of the BATTERY spring are down in the holding grooves and that the lower spring bracket is not distorted so that FIGURE 63 To adjust slightly loosen the screw holding the upper contact bracket and using ST 282 to raise the bracket see Figure 65 and tapping the top of the bracket to lower the contact Keep the con tacts in perfect alignment when adjusting Be sure that the screws are tightened with suit able lock washers and re check the gap after tightening the bracket Screws Re install the spiral spring being sure that the correct spring is used and that both ends of the FIGURE 65 52 AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued the spring is not vertical 9 Check armature air gap Test with pin gauge This is to be measured on the contact side as shown in Figure 61 and next to the armature stop pin as shown in Figure 62 _ To test connect a test light as shown in Figure 63 in series with the F terminal the regulator base and a battery With the low limit pin gauge in place depress the armature and the light should go out or dim With
51. ck current limiting regulator unit Connect the test ammeter in series between the regulator B terminal and the battery Increase the load on the generator by placing a lamp bank or other suitable resistance across the battery on the battery side of the ammeter DESCRIPTION These regulators are of the AND FUNCTION heavy duty type The De scription and Function and Car Test found on 5 pages 46 to 48 of this section is equally applic able to the heavy duty type regulators The main difference is the size and the fact that on some of the heavy duty regulators a second winding is used on the current limiting regulator This sec ond winding is connected in series with the gen erator field circuit and is connected so that rise and fall of the field current accelerates the action of the curr nt regulator armature This causes the cycles of operation to occur at suffi ciently high frequencies to limit the output to minimum fluctuation The ammeter should read within 5 of the am perage stamped on the nameplate of the regu lator If the amperage is outside the limits adjust the current regulator unit by varying the spring ten sion This is done by bending the lower spring bracket with ST 283 See Figure 69 Replace the cover after each adjustment and make a flash test POLARIZING Generators should always be polarized before running on car or bench
52. cludes an accurate indicating ammeter gradu ated in 1 ampere readings with heavy short leads an accurate indicating voltmeter gradu ated in 1 volt readings and a reliable ther mometer The resistance of the test ammeter must not exceed 1 volts at 10 amperes or 01 ohms Instru ments which have resistance higher than this will make it impossible to check or adjust the units x with the necessary accuracy peu The drop in voltage from the regulator to the battery or from the generator to the regulator must not exceed 1 volt when the generator is charging 10 amperes At this same charging rate the voltmeter should not show a reading when measured from the regulator base to the battery ground post the generator frame to the regulator base or from the generator frame to the battery ground post GATTERY FIGURE 50 AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued p Connections Disconnect the wire from the reg iator B terminal Connect one ammeter lead to the regulator B terminal and the other am meter lead to the lead removed from this terminal as shown in Figure 50 One voltmeter lead should be connected to the regulator B terminal on the regulator side of the ammeter connection while the other voltmeter lead is to be connected to the terminal marked GD or to the base of the regu lator Alt the connections are not made in this manner false r
53. e replaced 4 Lubrication Motors having oilers should have 5 to 10 drops their holders and make full contact on the com 74 of a good grade of S A E No 20 oil added each 5000 miles STARTING MOTOR OVERHAUL At intervals of approximately 25 000 miles the starting motor circuit should be thoroughly checked and the motor removed from the car for cleaning and checking 1 Starting Circuit The starting circuit should be inspected to be sure all connections are clean and tight and that the insulation on the wires is not worn or dam aged The starting circuit should be given a voltage loss test to make sure there is no loss of starting motor efficiency due to high resistance connections See Figure 95 In making this check the voltage loss from the battery terminal to the starting motor terminal should not exceed 12 volts maximum for each 100 amperes The loss in voltage between the battery ground post and the starting motor frame shovld not exceed 12 volts maximum for each 100 amperes if the voltage loss is greater than the above limits the voltage should be measured over each part of the circuit to locate the resistance causing voltage loss When measuring the voltage loss across solenoid xdi SETS tier ee ESA PT ER 4 i 1 1 1 AUTO LITE ELECTRICAL EQUIPMENT STARTING MOTORS AND SWITCHES Continued
54. eadings will be obtained due to e voltage loss in the current connections DP thermometer should placed 50 that its E bulb is approximately two inches from the side of the regulator must not touch the regulator 24 Battery This must read 1 275 to 1 280 specific gravity If the car battery is discharged substitute mporarily for test purposes a fully charged bat tery in good condition of the same type and M capacity Test Start the engine set the throttle for speed equivalent to approximately 30 M P H Run the engine for not less than 15 minutes with car hood up before taking meter readings With a generator charge of 10 amperes the volt meter should show a reading according to the specification figures given for the regulator under test at the temperature shown by the thermom eter With readings according to these figures the voltage regulator unit can be passed as func tioning correctly See pages 65 to 70 for com plete test data To test the current limiting regulator the same connections as noted above are used Add an Fi electrical load ofa current value in excess of the a amperes noted on the name plate of the regu lator at a point between the car ammeter and the battery This load may consist of a bank of standard head light bulbs or a carbon pile rheo stat If the current limiting regulator is function ing correc
55. good ground contact Brushes that are soldered to the field coil lead should be unsoldered and have the loop in the field coil lead opened The new brush pigtail should be inserted to its full depth in the loop and then clinched before resoldering good solder ing job must be done to insure no loss of starting motor efficiency due to a poor contact AUTO LITE ELECTRICAL EQUIPMENT STARTING MOTORS AND SWITCHES Continued Brush spring tension should be checked with a spr ng scale See specifications on page 81 To check the tension on swinging type brushes hook the scale under the brush screw tight against the brush and exert the pull in a line parallel to the side of the brush Take the reading just as the brush leaves the commutator When checking the tension of reaction type brush springs hook the scale under the brush spring near the brush and pull on a line parallel with the side of the brush Take the reading just as the spring leaves the brush If the brush spring tension is too low there will be a loss of efficiency due to poor brush contact If the tension is too great the commutator and brushes will wear excessively and have short life is therefore important that the brush spring tension be kept within the limits specified To change reaction type spring tension twist the spring holder with long nosed pliers On swing ing type brush holders it is necessary to remove 3 the s
56. henever a check of TC regulator action is made The voltmeter used to check TC regulators should be graduated in 1 volt readings If the test is made on ihe car a variable resistance should be connected in series in the charging circuit for proper control of the generator volt age 1 Visual inspection visual inspection of the unit should be made for a Evidence of burning or abnormal high tem peratures at the coils contacts insulation external terminals or any other point b Loose connections resulting from poor sol dering c Loose nuts on the bottom of the magnet cores loose rivets or screws All nuts and screws must have lock washers 2 Contacts The contacts can be cleaned by filing parallel ea ALL OF MAGNETIC LINES PASSING THROUGH ARMATURE NONE THROUGH MAGNETIC BY PASS MORE PULL ON ARMATURE FIGURE 46 eee renner he ERP AN GIN AA ROT NN RR IIT pi CERA FH RINGS erroe Rm Troes p we AO MRNAS KE e SUR i WED tret etii rtr ry ary mc E Mr eet tive Cod AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued FIGURE 47 with the length of the armature with a very fine file ST 290 recommended so that they are free from pits or burning After filing the contacts should be cleaned with refined carbon tetra chloride to remove any dirt or grease Pull a piece of clean linen t
57. idence of water having been inside of cover 15 Incorrect bent or distoried armature spring In case of doubt it is recommended that the spring be replaced 16 Broken or altered carbon resistors 17 Broken gaskets 18 Incorrect wiring connections between units See pages 65 to 70 for complete test data on VR type regulators CONTACTS The contacts should be cleaned by filing paral lel with the length of the armature with a very fine file ST 290 recommended so that they are free from pits or burning After filing the con tacts should be cleaned with refined carbon tet 7 Use flat gauge ST 281 3 034 to 038 be rachloride to remove any dirt or grease Pull a clean piece of linen tape between the contacts to remove any residue CARBON RESISTORS 1 Check the resistance of the carbon resis tors They should be removed from the regulator and checked with ST 284 ohmeter See Figure a On ihose regulators having more than one resistor it is extremely important that they be re placed in their proper position FIGURE 52 CIRCUIT BREAKER UNIT 2 Check resistance of circuit breaker voltage winding An accurate reading ohmeter ST 284 is _ 4 needed for this test and is made by disconnecting the voltage regulator lead from the circuit break er yoke and measuring from th A terminal to a ground on the base Connections are shown in Figure 52 e 3 Check the arma
58. ing Test Specifications IGNITION COILS teeter tenes 7 yee RELAYS AND REGULATORS CB CBA and RA Circuit Breakers itam n i 4 f Description and 40 SERVICE TOOLS Maintenance 40 RN STARTING MOTORS AND SWITCHES Test sss 41 Description and Function T lat s Pegy Tt Maintenance Procedure Description and Function 4 _ Motor Test Specifications Maintenance Procedure 42 Overhaul Proced r 71 Testing Adjusting sss 44 Switch Tests and Specifications Test Specifications 1 045 oT WINDSHIELD WIPERS EW and EWB and EWC Series EWD and EWE Series Specifications An Complete technical information on all Auto Lite equipment is included in the Service Manual Binder which i is in the possession of every Auto Lite Service Station Should additional information be required on dny of the equipment covered ae E E in n manual or n any Auto unit hot covered in this book it E A RE 1 4 3 In order to meet the demands for accurate re sults automotive service men must be skilled in the art of measurement This includes the use of
59. ith starting motors having a Bendix drive FIGURE 90 and is mounted separate from the motor It has a set of contacts that are opened and closed by mechanical action The contacts are designed for the large currents in a starting circuit Spring action is used to open the contacts to give a clean break and to minimize arcing The second type of manual switch is shown in Figure 91 and is remote controlled from the dash FIGURE 91 by a Bowden wire This type is also used on start ing motors using a Bendix drive The third type such as shown in Figure 92 is mechanically closed by depressing the clutch FIGURE 92 28 i Sp i eS at ci tuu sinat pascat sicci gat CRORE xa utc HEAD o AE Lii NE a AUTO LITE ELECTRICAL EQUIPMENT STARTING MOTORS AND SWITCHES Continued pedal and has a vacuum release and vacuum re lease lock to prevent operation of the starting motor when the clutch pedal is depressed while ihe engine is running With the engine not run ning depressing the clutch pedal closes the start ig switch thru cam A latch B and pressure arm C When the engine starts the latch B is lifted thru a connection to the vacuum diaphragm so that it disengages with the cam and the switch is opened by spring action As long as the engine continues to run the latch is held in the disen gaged position so tha
60. ity to crank the engine and sup ply enough electrical energy for the ignition system for starting the engine As the automobile has developed there has been an increase in the number of electrical uses The lights have been increased in number and capacity electric horns have become standard equipment electric windshield wipers are being used and the newer cars are using solenoid con _ trolled transmissions electric window lifts radios and many other electrical accessories These de velopments have come gradually and with each new use of electricity if was necessary to increase the capacity of the generator There are two main types of generators These are the third brush generator and the shunt gen erator THIRD BRUSH GENERATORS The output of third brush generators is con trolled by one of the following methods Adjustable third brush Adjustable third brush and two charge regu lator Adjustable third brush and vibrating voltage regulator Fixed third brush and vibrating voltage regu lator 1 Third Brush Control With this type of control the output is varied by changing the voltage applied to the field coils by moving the third brush Moving this brush in the direction of armature rotation increases the output while moving it against armature rotation decreases the output Figure 30 shows a typical output curve The internal wiring of a typical AMPERES
61. l list of Auto Lite gen ABBREVIATIONS USED iN THE FOLLOWING erators shows the rotation type of control test TABULATION to which it is set and the brush spring tension CW Clockwise rotation at the drive end CCW Counter clockwise rotation at the drive Test specifications on the following generators end are shown on page 39 CB Third brush control with circuit breaker NOTE Where the suffix letter has been omit TC Third brush and two charge regulator control ted the test data is the same as given for the straight number In a few instances the test data lator is not the same and in such cases the units are CVR Shunt type with vibrating current and listed separately voltage regulator I Spring j Spring Rot Test Tension Rot DEM Test Tension Unit Control Ounces Unk D E Control No Ounces CW GAE 0 90 96 GAR 4316 CCW CB GAR O 17 99 CCW CB GAE 0 90 96 GAR 4502 CW GAR O 18 22 CW GAE 0 90 96 GAR 4513 CW CB GAR O 18 22 CW TC GAE 0 90 96 GAR 4515 GB GAR O 18 99 CCW TC GAE 0 290 96 GAR 4518 CCW 0 18 99 COW 0 90 26 GAR 4590 CCW CB GAR O 18 99 CW 0 90 96 GAR 4521 CW CB GAR O 18 22 CW CB GAE 0 20 26 GAR 4599 Cw GAR O 18 99 CW CB GAE 0 20 95 GAR 4594 CW CB 0 18 99 CW TC GAE 0 90 26 GAR 4595 CW CB GAR O 18 99 CW TC GAE 0 90 96 GAR 4597 CCW CB GAR O 17 92 0 90 96 GAR 4534 CW GB GAR 0 18
62. l of the ammeter for the 50 ampere scale The fourth binding post is connected to the negative ammeter terminal for the 10 ampere scale Two small binding posts are provided between the second and third current carrying binding posts for the use of external shunts The following FIGURE 3 shunts Figure 3 are available with calibrated leads for connections to the P E T Set 100 ampere capacity Part Number ST 232A 2 200 ampere capacity Part Number ST 232A 3 500 ampere capacity Part Number ST 232A 1 1000 ampere capacity Part Number ST 232A 4 The voltmeter leads are permanently attached to the instrument and are 27 long with alligator clips on the ends for ease in making connections The positive lead is colored red and the negative lead is black Ammeter leads are No 8 flexible cable 37 long and have pin terminals on one end for connecting to the current carrying binding posts and special clips on the other end The positive lead is red and the negative black The ammeter lead clips have a long tooth on each corner so that they may be securely connected to wires with screw holes in the terminals AUTO LITE ELECTRICAL EQUIPMENT SERVICE TOOLS Continued GAUGE TEST SET METAR GAVR 4 meu mnnn THE ELECTRIC AUT LITE L Tonnar 5 3109 COO FIGURE 4 ST 262 V C P TEST SET This test unit Figure 4 is a very compact set of gauges for general automotive testing
63. lator unit in operation With the addition of a current load great enough to lower the battery voltage below the operating voliage of the voltage regu lator the contacts will remain closed and the gen erator will maintain its maximum charging rate The voltage regulator is compensated for tem perature variations through the use of a nickel iron magnetic by pass whereby a higher voltage is required to vibrate the contacts under cold operating conditions than is required under hot operating conditions This is necessary as it re quires a higher voltage to charge a battery when it is cold than when it is hot CURRENT LIMITING REGULATOR UNIT The current limiting regulator unit used with shunt type generaiors has an electromagnet with a winding of heavy wire which is connected in series between the generator A terminal and the series winding of the circuit breaker so that the entire output of the generator flews through it When the generator output reaches its pre determined maximum the ampere rating of the generator with which the regulator was designed to operate the regulator contacts are opened inserting a resistance in the field circuit which reduces the ampere output of the generator mediately upon the dropping of the output the contacts close shorting out the resistance and the AUTO LiTE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued output rises completing one cycle of operation
64. ldering should be reconnected Where resoldering is necessary care must be taken that a good clean contact is made Do not use acid for soldering flux After the regulator has been compleisly 3 assembled its bottom should be struck sharply on the bench several times fo be sure that all parts are settled in place When doing this be sure that it is struck squarely on all four mounting lugs Re check all adjustments TESTING AND ADJUSTING NOTE THE COVER MUST BE ON THE REGU LATOR WHEN TAKING READINGS OR WHEN THE UNIT IS BEING HEATED BY OPERATION PRIOR TO TAKING READINGS THIS IS NEC ESSARY DUE TO THE FACT THAT THE COVER HELPS RETAIN THE HEAT When testing or adjusting regulators care must be taken that it is mounted firmly and in a place where there is no vibration It must also b tested in the same position as it is mounted on the car Care must be taken in making the various test made so that the resistance of all connect ns does not exceed 01 ohms with a 10 ampere nections are not recommended Flexi mended as experience shows that these prevent high resistance connections from entering into the test circuit it is suggested that a single earphone 2000 ohms or higher be attached to the F terminal and ground and used for listening to the regu lator armature vibrations and so obtain an ac curate indication
65. nal connect ing with the starter motor and a shunt winding connected from the relay stationary contact to ground Between the time the relay contacts close and the main switch is closed both windings have current flowing thru them causing the solenoid to exert its strongest magnetic pull on the plunger thus assuring positive meshing of the pinion When the main switch contacts close the series winding is short circuited and the plunger is held in place by the shunt winding only This results in a minimum amount of arcing at the relay contacts when the switch opens MAINTENANCE PROCEDURE A periodic inspection should be made of the starting circuit While the interval between these checks will vary accordng to the type of service if should under normal conditions be made every 5000 miles At this check the following points should be inspected 1 Wiring A visual inspection should be made of all wires to be sure that none are broken and that all gt connections are clean and tight 2 Commutator If the commutator is dirty or discolored it can be cleaned with 00 sandpaper Blow the sand _ out of the motor after cleaning Should the commutator be rough or worn the motor should be removed from the egine for cleaning and reconditioning Instructions for the servicing of starting motors are given later in this section 3 Brushes The brushes should slide or swing freely in mutator Worn brushes should b
66. nickel iron across the top of the magnet core The magnetic conductivity of this by pass gradually increases as its temper ature is reduced Thus at low temperatures much of the magnetic pullof the corewhich would norm ally affect the cutting in of the field resistance flows thru this by pass instead of the regulator armature and results in a higher generator volt age being required to open the contacts and cut in the field resistance On the other hand at high temperatures the magnetic conductivity of the by pss is reduced thus allowing the magnetic pull the core to have full effect on the regulator armature and cut in the field resistance at a lower generator voltage See Figures 45 and 46 All TC regulators have an easily accessible i have the resistance controlling the gen era or output mounted externally and a cover which seals the working parts of the unit from dust MAINTENANCE When testing TC regulators PROCEDURE the car and checked on the test bench where they should be removed from temperatures are known and are fairly constant PART OF MAGNETIC LINES PASSING THROUGH MAGNETIC BY PASS LESS PULL ON ARMATURE FIGURE 45 AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued Where it is necessary that the regulator be checked on the car be sure that the car has stood in a uniform temperature for at least 15 min utes thermometer with iis bulb placed near ihe regulator should be used w
67. ntacis consist of one movable contact mounted on an armature oper d by the electro magnet while the other is a contact These contacts are held open by an armature spring The sex er unit 95 follows ence of operation of the circuit brea When the generator is not running tacfs are open When the generator AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS CB and RA CIRCUIT BREAKERS the voltage builds up at the generator terminal and in the shunt coil As soon as the voltage reaches the value for which the circuit breaker is calibrated there is sufficient magnetism created by the shunt coil to pull down the armature clos ing the contacts automatically connecting the generator to the battery With the contacts thus closed the current in the series coil is flowing from the generator to the battery or in the same direction as the current in the shunt coil so that the pull on the armature is increased by mag netism of the series coil As the engine is stopping and the generator loses speed the voltage falls As soon as the generator voltage drops below the battery ter minal voltage the current flows from the battery to the generator reversing the direction of cur rent in the series coil so that the magnetism created by the series coil is opposed to the mag netism created by the shunt coil reducing the magnetic pull on the armature and the spring
68. o 8 0 amperes at 3 0 volts Shunt coil only 7 0 to 8 0 amperes at 3 0 volts Series coil only 27 0 to 30 0 amperes at 3 0 volts Series coil only 38 0 to 42 0 amperes at 3 0 volts SS 4200 12 volt units Relay Contacts close 7 0 to 9 0 volts Contacts open 3 0 to 5 0 volts Solenoid Shunt coil only 1 8 to 2 2 amperes at 5 0 volts Series coil only 15 5 to 18 5 omperes at 5 0 volts AUTO LITE ELECTRICAL EQUIPMENT Type DI DI DN DY MAB MAD MAJ STARTING MOTORS AND SWITCHES Continued STARTING MOTOR TEST SPECIFICATIONS Spring Tension Ounces 56 60 56 60 56 60 36 40 42 53 42 53 42 53 38 61 No Load Amps 60 50 50 60 60 67 Min RPM 4500 Volts 3 6 0 3 6 3 5 4 0 4 0 4 0 Stall Test Amps 730 410 810 720 Min Ft Lbs 29 2 16 6 39 0 29 4 22 5 18 5 17 0
69. of Voltage Winding 8 35 39 c 35 39 70 7 85 89 Armature Air Gop MEE 010 7 030 _ 010 030 7 010 030 lt Contact Point Gap D n 015 045 gt 015 7 045 015 045 Point Closing Voli PINE 2 64 70 6 47 0 6 5 7 25 ning i OEC RATE 1 03 5 1 0 3 5 5 2 50 39 33 29 33 29 33 1034 038 044 046 047 049 005 005 min m s tetas 815 8 15 7 34 8 07 2 8 07 729 800 8 00 725 Lr 7 93 721 3785 0002 7 85 22 716 7 78 7 78 2212 5 MI 2221 708 zm 25 25 15 181020 10512 AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued i VRB VRD VRE VRF VRJ VRK VRO VRP VRR VRS VRT VRU VRV VRW and VRX REGULATORS DESCRIPTION AND FUNCTION of VR regulators they all op erate on the same general principle The follow While there are several types ing description of their construction and oper ation is given so that in making the tests as out lined they may be made more intelligently The VR regulators used with third brush con trolled generators have two units and two func tions to perform namely the closing and opening of the circuit between the generator and battery _ by means of the circuit breaker and the holding of the voltage at a predetermined value by means of
70. on 24 and 32 volt circuits For the 0 10 volt scale there are 100 divisions so that each represents 1 volts Accuracy of the voltmeter is held within 1 of all parts of the scale except between and 9 volts where it is held to 2 accuracy This is necessary as this latter portion of the scale is the most commonly din festing 6 volt circuits The ammeter has two scales 3 0 10 ampere scale for testing low current draw 2215 0 50 ampere scale for general use in test ing automotive circuits Depressed zero scales are built into the instru ment to avoid the necessity of changing the am meter connections to obtain negative readings such as the amperes discharge required to open circuit breakers The accuracy of the ammeter is held within 276 of full scale deflection A amp ohm rheostat of 50 ampere capacity is included in this instrument for use in setting volt age to test specifications 5 2 on the instrument The first one on the right hand H side marked Resistance In is connected to the rheostat and is in series with the positive terminal of the ammeter 721 The second binding post marked Resistance There are four current carrying binding posts m AUTO LITE ELECTRICAL EQUIPMENT SERVICE TOOLS Continued Out is a direct connection to the positive term inal of the ammeter without passing through the rheostat The third binding post is connected to the negative termina
71. onary contact oe 2 Check the armature air gap with the cor tacts open s Use flat gauge inserted on the contact side of the brass pin in the core as shown in Figure 72 AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued 3 Check gap of the contacts This gap should be 015 minimum but will possibly be more than this in actual adjustment See Figure 73 Adjust by bending the supporting arms of the stationary contacts being sure that both sets of contacts in perfect alignment and that con tact is made on both sets of contacts at the same inl time Use a straight edge across the top of the O 26 s 8 contact brackets to check their alignment FIGURE 75 VOLTAGE REGULATOR E 4 Check the resistance of the winding An accurate ohmeter is needed for this test To test disconnect both leads from the base and measure between the terminals as shown in Fig ure 74 f 5 Check armature air gap with contacts just breaking Test with pin gauge as shown in Figure 75 This measurement is to be taken on the contact side and next to the brass armature stop as illustrated in Figure 76 AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued FIGURE 7 To test connect a 3 C P light as shown in Fig ure 77 in series with the A and F terminals and a bat
72. ound the commutator and turn the armature slowly in the direction of rotation Blow the sand and carbon dust out of the motor after sanding When installing the yoke and overrunning clutch the yoke shoes should be assembled with the radial side toward the pinion end of the clutch 8 Lubrication Auto Lite starting motors are equipped with absorbent bronze bearings These bearings are able to absorb 25 of their own volume in oil Most of the drive end and intermediate bear ings do not need any attention The commutator end bearing and some of the intermediate bear ings are equipped with oilers which should be given 5 to 10 drops of medium engine oil every 5000 miles Do not over lubricate as excessive lubrication will damage commutators and insu lation Gear reduction motors have a grease pocket in the gear chamber which should be filled with a high melting point grease when assembling If this gear reduction is provided with a grease cup it should be given one turn every 5000 miles If an oiler is provided it should be given 5 to 10 drops of medium engine oil every 5000 miles When the starting motor is serviced the bear ings should be soaked in oil and the bearing seats should be given a light wipe of oil 9 Bench Test The motor should first be checked to see that the free running voltage and current are within specifications See page 81 for test data To test connect the motor to a battery and voltmeter
73. pring and arm and bend the spring to change the tension _ 3 Commutator Check the commutator for wear or discolor ation If the commutator is only slightly dirty or discolored it can be cleaned with 00 or 000 sandpaper Blow the sand out of the motor after cleaning the commutator If the commutator is rough or worn the armature should be removed and the commutator turned down in a lathe 4 Armature The armature should be visually inspected for mechanical defects before being checked for shorted or grounded coils For testing armature circuits it is advisable to use a set of test probes such as illustrated in Fig ure 96 VOLT LINE INSULATED HANDLES FLEXIBLE LEADS FIGURE 96 test the armature for grounds touch one point to a commutator segment and touch the core or shaft with the other probe Do not touch the points to the bearing surface or to the brush surface as the arc formed will burn the smooth finish If the lamp lights the coil connected to the commutator segment is grounded To test for shorted armature coils a growler is necessary The armature is placed against the STEEL STRIP HELD ON ARMATURE SLOT 57 54 5 76 a aaa AD RA MR i aa La e ai ant nt TR aA AUTO LITE ELECTRICAL EQUIPMENT STARTING MOTORS AND SWITCHES Continued core and a steel strip held on
74. pt that the posi tion of the third brush is not adjustable SHUNT GENERATORS With the development of high output gener ators it became desirable to eliminate the de crease in output at high speeds and also to lower the generator speed at which the maximum out put is produced This was done by using a shunt generator and eliminating the third brush con trol With a shunt generator it is necessary to provide some method for limiting the maximum output of the generator to a safe value The current limiting regulator was developed for this purpose When a voltage and current limiting regulator is used in conjunction with a shunt gen erator a charging rate is obtained that is fully dependent on the requirements of the circuit Such a curve is illustrated in Figure 36 Figure 37 AMPERES GENERATORS Continued shows the internal wiring of a shunt generator and a voltage and current limiting regulator MAINTENANCE periodic inspection should PROCEDURE cuit The interval between these checks will vary be made of the charging cir depending upon the type of service Dirt dust and high speed operation are factors which con tribute to increased wear of the bearings brush es etc Under normal conditions an inspection of the generator should be made each 5000 miles
75. rning the com mutator the mica should be undercut to a depth of 1 32 When undercutting the mica the cut should be square and free from burrs The maxi mum eccentricity of the commutator is not to ex ceed 0003 inches For testing armature circuits it is advisable to use a set of test probes such as shown in Figure 39 770 VOLT LINE TEST POINTS INSULATED HANDLES FLEXIBLE LEADS FIGURE 39 To test armatures for grounds connect one point to the core or shaft not on bearing sur faces and touch a commutator segment with the other probe If the lamp lights the armature winding is grounded and the armature should be replaced To test for shorted armature coils a growler Figure 40 is necessary Place the armature on the growler and hold a thin steel strip on the armature core The armature is then rotated slowly by hand and if a shorted coil is present STEEL STRIP HELD ON ARMATURE SLOT 47 em gt r PETIT Oe FIGURE 40 the steel strip will vibrate 3 Field Coils Using the test probes illustrated in Figure 39 check the field coils for both opens and grounds To test for open coils connect the probes to the two leads of each coil If the lamp fails to light the coil is open and should be replaced To test for grounds place one probe on the generator frame and the other to the field coil terminals If a ground is present the lamp will light and the coil should be replaced 4
76. t ing the bridge supporting the sta tionary contact being sure that the FIGURE 59 the contact side as shown in Figure 61 and nt xt contacts are perfectly aligned This adjustment is shown in Figure 59 VOLTAGE REGULATOR 5 Check the resistance of the winding An accurate reading ohmeter ST 284 is needed for this test To test measure from the lead disconnected from the circuit breaker yoke to ground See Figure 60 for these connections 6 Check and see that the spring upon which the movable contact is mounted is straight and that it is approximately parallel with the arma ture FIGURE 60 7 Check armature air gap FIGURE 61 _ Test with pin gauge This is to be measured on io w AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued spring are down in the holding grooves and that the lower spring bracket is not distorted so that the spring is not vertical CURRENT LIMITING REGULATOR UNIT 8 Check and see that the spring upon which the movable contact is mounted is straight and FIGURE 62 to the armature stop pin as shown in Figure 62 To test connect a 3 C P test light as shown in Figure 63 in series with the F terminal the regulator base and a battery With the low limit pin gauge in place depress the armature and the light should go out or dim With the high limit gauge in place the light should stay lighted when the arm
77. t the clutch pedal can be operated without dosing the switch The last type such as shown mounted on the motor illustrated in Figure 86 is used only on motors with overrunning clutches It is controlled by a foot pedal that is connected by linkage to the shift yoke which moves the clutch pinion into mesh and then closes the switch contacts Solenoid starting switches may be divided into two types those which magnetically close the starting circuit and those which not only close the starting circuit but also shift the overrunning clutch pinion CAR FRAME FIGURE 94 PLUNGER SPRING CONTACT DISC PLUNGER SPRING PLUNGER MAGNETIC COL FIGURE 93 The first of these types is shown in Figure 93 and is used with Bendix drive motors It magnet ically closes the circuit between the storage bat tery and the motor and is controlled by a push button located on the instrument panel The second type not only magnetically closes the starting circuit but it also shifts the overrun ning clutch pinion into mesh with the flywheel GROUND TO SWITCH COVER AUTO LITE ELECTRICAL EQUIPMENT STARTING MOTORS AND SWITCHES Continued gear It is controlled by a push button mounted on the instrument panel thru a relay mounted within the switch See Figure 94 The solenoid coil includes two windings a series winding connected from the relay station ary contact to the main switch termi
78. tage be yond that required to close the contacts decrease the voltage until the contacts open 7 Second Method For circuit breakers with the upper contact mounted directly on the arm ature s To test connect an ammeter in series between the battery and the B terminal The voltmeter _ is connected to the A terminal of the regulator BATTERY FIGURE 67 FIGURE 68 and to ground Be sure that the voltmeter con nections are on the regulator side of the ammeter connections to avoid loses due to poor connec tions See Figure 67 When testing increase the voltage slowly noting the voltmeter reading just before the contacts close Increase the charging rate to 15 amperes then reduce the charging rate noting the amperage discharge just before the contacts open ADJUSTMENTS To adjust the closing voltage adjust the arma AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued CIRCUIT BREAKER UNIT UP TO DECREASE CLOSING VOLTAGE CURRENT LIMITING REGULATOR UNIT LOWER SPRING BRACKET BEND DOWN TO INCREASE CURRENT SETTING BEND UP TO DECREASE CURRENT SETTING VOLTAGE REGULATOR UNIT FIGURE 69 ture spring tension by bending the lower spring bracket with ST 283 as shown in Figure 68 A very accurate method of checking this closing voltage is by connecting a headphone 2000 ohms or higher between the B terminal and the A terminal and taking the re
79. tarting motor is designed to crank the engine when the starting switch eloses the circuit between the storage battery and the motor The design of the starting motor depends upon the type and application of the engine on which it is to be used Starting motors vary as to size num ber of poles and number of brushes MOTOR DRIVES To transmit power to the flywheel of the en gine Auto Lite starting motors use either an over running clutch or a Bendix drive Some motors have a gear reduction between the armature and drive pinion to increase the power for heavy duty installations See Figure 85 T iea C O POST 4 GEQUVDEO BRUSH E TH w fo pM STSET wG SWITCH V7 7 qi ki im ape op INSULATED BRUSH FIGURE 87 In either case the action of the clutch is identical Figure 88 illustrates a typical overrunning clutch The clutch has internal splines to match the s on the armature shaft When the yoke lever i shifted either mechanically electrically the complete drive is moved along the armature shaft Els FIGURE 85 The overrunning clutch pinion may be shifted either mechanically through a starter pedal Fig ure 86 or electrically by a solenoid Figure 87 until the pinion meshes with the flywheel ring gear If the pinion teeth do not mesh with the flywheel teeth the movement of the yoke
80. tery With the low limit pin gauge in place depress the armature and the light should go out With the high limit pin gauge in place depres the armature and the light should stay lighted Use two fingers in depressing the armature one FIGURE 77 armature stop pin and a new uni on either side of the contact spring so that the contact spring is not touched The pressure should be applied near the center of the arm ature To adjust loosen the screws and raise or lower the armature contact stop Be sure that these screws are tightened with suitable lock washers Check and see that the spring upon which the movable contact is mounted is straight and that it is parallel with the armature 6 Check contact gap with the armature against the stop pin Figure 78 FIGURE 78 Hold the armature down with two fingers as as illustfated taking care that the contact spring is _ not touched df the gap is too small check to see that the bridge carrying the nickel iron shunt has been pushed down in assembly If the bridge is not pushed down the armature rivets will strike the shunt and prevent the contacts from opening sufficiently 5 The test figures shown are approximate only too much variation indicates wrong length to nit will be neede AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued FIGURE 79
81. the following essential service station tools 1 Voltmeter 7 Vacuum Gauge 2 Ammeter 8 Compression Gauge 3 Ohmeter 9 Coil Tester 4 Timing Light 10 Micrometers 5 Gap Gauges 11 Distributor Test Fixture 6 Feeler Gauges 12 Condenser Tester Several of these units have been developed to Auto Lite specifications as fine precision instru ments while others may be obtained from several dependable sources In handling electrical measuring instruments it should be remembered that they are extremely sensitive and delicately balanced They should not therefore be subjected to sudden shocks nor should they be subjected to excessive vibration A stand such as illustrated in Figure 1 is com paratively easy to make and will eliminate the vibration they receive when placed on the car with the engine running via x 51 STEEL pia x 18 STEEL 3 l on x ai sreen 2 4x20 sETSCREWS I ANGLE IRON 2 X49 xX woop PAINT BLACK z DIA x 18 STEEL BARS CHROME E u E wane prm irum jud inate obtain th sible scale so that indicc read accurately The veis has Jem 0 5 volt scale for testing high resistances and electrical devices operating at low volt ages 0 10 volt scale for general use 6 volt circuits 9 20 volt scale for general use 12 volt circuits 0 50 volt scale for general use
82. the high limit gauge in place the light should stay lighted when the arm ature is depressed Use two fingers see Figure 64 to depress the armature being careful not to touch the contact spring To adjust slightly loosen the screw holding the upper contact bracket and using ST 282 to raise ihe bracket see Figure 65 and tapping the top of the bracket to lower the contact Keep the con tacts in perfect alignment when adjusting Be sure that the screws are tightened with suit able lock washers and re check the gap after tightening the bracket screws TO Check the contact gap with the armature against the stop pin See Figure 66 Hold the armature down with two fingers being FIGURE 66 careful not to apply pressure to the spring sup porting the lower contact The test figures are approximate only too much variation indicates wrong length to the armature stop pin and a new unit will be needed RE ASSEMBLING THE REGULATOR When all preceding checks and adjustments have been completed all the leads which have been disconnected either by the removal of a screw or by unsoldering should be re connected Where resoldering is necessary care must be taken that a good clean contact is made Do not use acid for soldering flux After the regulator has been completely i assembled its bottom should be struck sharply on the bench several times to be sure that all parts e are settled in
83. the voltage regulator unit The current limited by the conventional third brush action The VR regulators used with shunt generators three units each performing a distinct and independent function 1st the circuit breaker to close and open the circuit between the generator dnd battery 2nd the voltage regulator to hold thay system voltage at a predetermined value and 3rd the current limiting regulator to control the maximum ampere output of the generator CIRCUIT BREAKER UNIT operation and function of the circuit breaker unit is the same as described on page 40 VOLTAGE REGULATOR UNIT The electromagnet of the voltage regulator unit has a single winding which is shunt con nected directly across the battery charging cir cuit This connection is made at the circuit breaker dn order that the batt ry rather than generator voltage will control its operation When the volt age rises to a predetermined value this winding is energized sufficiently to cause the voltage regu lator contacts to open thus cutting in a resistance in the generator field circuit which reduces the generator voltage immediately upon the drop ping of the voltage the contacts close shorting out the resistance and the voltage rises again thus completing one cycle of operation These cycles occur at frequencies necessary to maintain the voltage at correct vaiues as long as the volt age is high enough to keep the voltage regu
84. tly the test ammeter will show a read ing of the maximum amperes shown on the name plate of the regulator with an allowed variation of 5 If the unit does not operate according to speci fications it should be removed from the car and thoroughly checked and adjusted MAINTENANCE PROCEDURE VISUAL INSPECTION Before making any tests or adjustments it is recommended that a close visual inspection be given the regulator with special emphasis being paid to the following points 1 Broken regulator seal 2 Evidence of burning or abnormal high temperature at the coils contacts insula tion external terminals or any other point It is suggested that this test be made with a magnifying glass 3 Loose connections which result from poor soldering 4 Loose nuts on the bottom of the magnet cores loose rivets or screws All nuts and screws must have lock washers 5 Loose contacts 6 Misalignment of contacts 7 Bent armature either at the contact or hinge end The armature should be per fectly straight from one end to the other 8 Magnet yoke bent 9 Bent armature hinges 10 Reversed bimetal hinges on the circuit AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued breaker unit When correctly installed the brass side must be up 11 Stripped or crossed threads on any screw or nut 12 Corrosion due to salt or acids 13 Broken ground straps 14 Ev
85. tput is reduced This prevents the increase in voltage obtained when high resistance occurs in a circuit without a vibrating type regulator or with a two charge regulator This elimination of high volt age increases the life of lamp bulbs and of the ignition system When the vibrating type regulator is used with a third brush generator it is possible to use a much higher capacity generator without danger E EOE CEE bM atti of overcharging the battery The maximum cur rent is still controlled by the third brush A typi cal charging curve and wiring diagram of a third brush generator with vibrating voltage regula aros gi sova Db em wi tion are shown in Figures 34 and 35 The heavy APPROXIMATE OUTPUT TO FULLY CHARGED BATTERY AND WITH NO CONNECTED LOAD harta 2400 3200 4000 4800 5600 6400 GENERATOR REM 1606 B ai RE ae bei iie edt Rye dee am FIGURE 34 AUTO LITE ELECTRICAL EQUIPMENT INSULATED MAIN BRUSH B FIGURE 35 line indicates the maximum output and the dotted lines indicate the decrease in output as the battery becomes charged 4 Fixed Third Brush with VR Regulator The operation of this type is identically the same as the preceding type exce
86. ture air gap with the con tacts open AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued it does not rub against the side of the armature On early production regulators the armature stop was at the end of the armature as shown in Figure 55 To adjust bend this stop B being sure that it does not rub against the end of the arma FIGURE 53 tween the magnet core and the armature as close to the hinge as possible as shown in Figure 53 FIGURE 56 ture Other early regulators had the armature stop in the center as is shown in Figure 56 On this type bend the stop C being sure it does not rub against the side of the slot FIGURE 54 227 Adjustment of the air gap is made by bending FIGURE 57 On those applications where an indicating lamp is used instead of an ammeter the regulator circuit breaker unit has a second set of contacts To adjust the armature air gap on this type of unit bend the upper contact bracket C Figure 57 as required BE SURE THAT THE BRACKET AUTO LITE ELECTRICAL EQUIPMENT RELAYS AND REGULATORS Continued SUPPORTING THE UPPER CONTACT DOES NOT RUB AGAINST THE SIDE OF THE ARMATURE OR TOUCH THE YOKE AND THAT THE CONTACTS ARE ALIGNED FIGURE 58 4 Check the gap of the contacts when open See Figure 58 This gap should be 015 mini mum but will possibly be more than this in actual adjustment Adjust by expanding or contrac
87. u checking the air gap between the armature and AUTO LITE ELECTRICAL EQUIPMENT SERVICE TOOLS Continued FIGURE 7 core The set includes two each of ST 272 1 027 inch thick gauge and ST 272 2 040 inch thick gauge ST 281 VR REGULATOR GAUGES Figure 8 This list includes all necessary gauges for the s n sT 281 3 sr 28 4 wae lt _ 57 81 o r J FIGURE 8 adjusting and setting the air gaps of the TC and VR type regulators namely ST 281 1 Armature Core Air Gop Gauge 040 042 ST 281 2 Armature Core Air Gap Gauge 0595 0625 ST 281 3 C B Armature Core Air Gap 034 038 6 281 4 Armature Core Air Gap 055 062 ST 281 5 Armature Core Air Gap Gauge 047 049 ST 281 6 Armature Core Air Gap Gauge 034 038 ST 281 7 Armature Core Air Gap Gauge 048 051 ST 281 9 C B Armature Core Air Gap 031 034 57 282 VR REGULATOR ADJUSTING TOOL Figure 9 FIGURE 9 This tool is designed for adjusting the air gap of vibrating type regulators 5 283 REGULATOR SPRING TENSION ADJUSTING TOOL Figure 10 FIGURE 10 This tool is used to adjust the armature spring tension on all two charge and small type vibrat ing voltage regulators ST 284 OHMETE

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