Have I Found the Culprit?

[Joe Flanagan]

I have performed the tests outlined in the manual to see if my generator is producing the proper voltage (amps is another story--I don't have the right meter for that). Anyway, with the engine running at about 1500 + RPMs, I don't have a single volt coming out of the generator. Close, .8, but not one whole volt.

So I followed the next step in the manual and put a test light on the armature terminal while revving the engine. It should light up and it did not. I tried several different ground points just to make sure and no light. So time to remove the generator for further inspection and tests.

[BobT-47P15]

Joe, do you have a generator repair shop in your area?

I have taken mine to such a place.....they can test them real

quick and easy and then fix what needs fixing.

Not as much fun as trying to do it yourself, but solves the problem

usually.

[Joe Flanagan]

I do, Bob. I was just trying to see if I could figure it out myself. But with the latest development, I'm thinking of giving in. I took the generator apart once again and discovered one of the wires from one of the terminals was so corroded it crumbled off in my hand. To the eye, it looked fine, but once I touched it, it came apart. So I cleaned everything up, soldered it back together, re-installed the generator and started it up. I was sure this would be the problem.

But it isn't. I still have a no-charge condition. One thing I noticed is that my brushes are not making good contact with the commutator head. I'd say that only about a third of the brush is in contact. Could this be my problem, and how do you fix something like that? When they're in their holders, the brushes look straight and they LOOK like they're in full contact with the commutator head. But if you look at the ends of the brushes, they're making poor contact.

[BobT-47P15]

Are the brushes new.......do they need to be replaced? They

wear down over time.

[Joe Flanagan]

They have plenty left on them but there are some chips. The chips are not in an area that makes contact with the head.

[Jim Yergin]

Joe,

I think you said that your amp meter showed neither a charge nor a discharge. A faulty generator might explain a lack of charge but wouldn't the amp meter still show a discharge when you hooked up the headlight?

Jim Yergin

[Joe Flanagan]

Jim,

My ammeter does show a discharge when I hook up a headlight. That's how I determined that the gauge was working. Right now, I'm getting ready to pull the generator again and see if I can figure out why the brushes won't make full contact with the commutator head.

[Jim Yergin]

Very good. I misunderstood your situation. Good luck, I hope you get it straightened out.

Jim Yergin

[Joe Flanagan]

I finally gave in and took the generator to a shop. The guy there tested it and said he couldn't get it to do anything at all. So at least I know that the tests I performed were accurate. He says the brushes look good to him and that he suspects the problem might lie in one of the field coils. He will call with an estimate, which I expect will be on the order of $200. This place wanted to rebuild my starter for about that amount. I did it myself. Put in new bushings and brushes and it now works great. I might have to dig into my pockets for this one, though.

[Don Coatney]

I finally gave in and took the generator to a shop. The guy there tested it and said he couldn't get it to do anything at all. So at least I know that the tests I performed were accurate. He says the brushes look good to him and that he suspects the problem might lie in one of the field coils. He will call with an estimate, which I expect will be on the order of $200. This place wanted to rebuild my starter for about that amount. I did it myself. Put in new bushings and brushes and it now works great. I might have to dig into my pockets for this one, though.

Did he do the "growler" test?

Also go here to learn more.

http://www.jalopyjournal.com/forum/showthread.php?t=278956&page=3

Here is another link.

http://www.tpub.com/basae/28.htm

You might also call George Asche and get a rebuilt price from him. He and his boys run a generator/starter repair shop.

[Joe Flanagan]

OK, thanks Don. I don't know if he did a growler test. I read about that in the manual. I didn't understand how you were supposed to hold a hacksaw blade or similar device on each bar of the armature while it's turning. I believe the test involves turning the thing, if I'm not mistaken. But with the engine running at a high idle, I put a test lamp on the armature terminal, grounded it, and it didn't light. The voltmeter also showed practically nothing coming out of the generator. I'll call George if these guys are outrageously priced.

[Flatie46]

Wow, $200 seems kinda high for a rebuild to me are the coils that expensive? Maybe I'm living in the past. One thing about it, I've read on here 6volt systems are reliable if everythings done right. Might be money well spent.

[Joe Flanagan]

I think what they quoted me for the starter was 170 and I thought that was high. Heck, I might just see if someone makes a rebuild kit.

[Phil Martin]

Does anybody sell new or rebuilt gens anymore?

[David Strieb]

remanufactured 6 and 12 volt generators and starters are on ebay all the time