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techtalk:ih:elec02a [2018/12/16 23:36] – hippysmacktechtalk:ih:elec02a [2023/12/30 01:32] (current) – hippysmack
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 ====== IH: Electrical System - Sub-02A ====== ====== IH: Electrical System - Sub-02A ======
 ====== Bench Testing a Generator ====== ====== Bench Testing a Generator ======
-Article by sifty of the XLFORUM ((http://xlforum.net/forums/showthread.php?t=1592463&page=42)) \\+Article by sifty of the XLFORUM ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/146604-first-harley-1975-xl1000-caf%C3%A9-project/page42?t=1592463&page=42)) \\
  
 Some simple diagnostic tests can be done with a multimeter. \\ Some simple diagnostic tests can be done with a multimeter. \\
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 {{  :techtalk:ih:elec:generator_drawing_1_by_sifty.jpg?direct&500|}} {{  :techtalk:ih:elec:generator_drawing_1_by_sifty.jpg?direct&500|}}
-  * Generators are fairly simple, they consist of; ((photo by sifty of the XLFORUM ((http://xlforum.net/forums/showthread.php?t=1592463&page=42))+  * Generators are fairly simple, they consist of; ((photo by sifty of the XLFORUM ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/146604-first-harley-1975-xl1000-caf%C3%A9-project/page42?t=1592463&page=42))
     * Field windings are designated "F" (attached to the case).     * Field windings are designated "F" (attached to the case).
     * Armature windings are designated as "A" (wound around the rotating shaft).     * Armature windings are designated as "A" (wound around the rotating shaft).
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 \\ \\
 \\ \\
-  
  
 ====== Brush assembly ====== ====== Brush assembly ======
  
 {{  :techtalk:ih:elec:generator_pic_by_sifty.jpg?direct&400|}} {{  :techtalk:ih:elec:generator_pic_by_sifty.jpg?direct&400|}}
-The brush plate is easily removable, and inspection/ cleanup should be straight forward. ((photo by sifty of the XLFORUM http://xlforum.net/forums/showthread.php?t=1592463&page=42)) \\+The brush plate is easily removable, and inspection/ cleanup should be straight forward. ((photo by sifty of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/146604-first-harley-1975-xl1000-caf%C3%A9-project/page42?t=1592463&page=42)) \\
 Care must be taken when installing the brush plate. \\ Care must be taken when installing the brush plate. \\
 Make sure that the brush- armature connecting wire is not pinched (can short circuit to the frame). \\ Make sure that the brush- armature connecting wire is not pinched (can short circuit to the frame). \\
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 Ensure the connecting wires are tightened in a position to allow full movement. \\ Ensure the connecting wires are tightened in a position to allow full movement. \\
 And make sure the bare end of the armature brush wire does not contact the case or end cap on assembly. And make sure the bare end of the armature brush wire does not contact the case or end cap on assembly.
 +
 ====== Terminal insulation ====== ====== Terminal insulation ======
- 
 The terminals must be insulated between where they go through the case and connect to the windings. \\  The terminals must be insulated between where they go through the case and connect to the windings. \\ 
 There will be some sort of fiber or plastic bushing around them at this point. \\ There will be some sort of fiber or plastic bushing around them at this point. \\
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 ====== Armature ====== ====== Armature ======
- 
 Testing on the Ohms scale between each commutator segment and the exposed iron core will indicate any short circuits to ground. \\ Testing on the Ohms scale between each commutator segment and the exposed iron core will indicate any short circuits to ground. \\
 Each segment should show very high resistance to ground (ideally in the Mega-ohms range). \\ Each segment should show very high resistance to ground (ideally in the Mega-ohms range). \\
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 With the generator cleaned, assembled and on the bench, some simple test with the multimeter in the Ohms scale can tell you a lot about its electrical health. \\ With the generator cleaned, assembled and on the bench, some simple test with the multimeter in the Ohms scale can tell you a lot about its electrical health. \\
 The figures noted here were the results from 2 generators (different models). \\ The figures noted here were the results from 2 generators (different models). \\
-They should be reasonably typical the standard 12V Harley generator. ((photo by sifty of the XLFORUM http://xlforum.net/forums/showthread.php?t=1592463&page=42))+They should be reasonably typical the standard 12V Harley generator. ((photo by sifty of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/146604-first-harley-1975-xl1000-caf%C3%A9-project/page42?t=1592463&page=42))
  \\  \\
  
 {{  :techtalk:ih:elec:generator_drawing_2_by_sifty.jpg?direct&400|}} {{  :techtalk:ih:elec:generator_drawing_2_by_sifty.jpg?direct&400|}}
-Field winding resistance: \\+**Field winding resistance**: \\
 Placing the leads across the A and F terminals will give you the effective resistance of the field windings (2 windings in series). \\  Placing the leads across the A and F terminals will give you the effective resistance of the field windings (2 windings in series). \\ 
 The armature circuit is not included as in a healthy generator there is no return path via ground to the meter. \\  The armature circuit is not included as in a healthy generator there is no return path via ground to the meter. \\ 
 This should be around the 5.8 ohm mark, a higher figure indicates a possible open circuit, and a lower figure may mean a winding is shorting out somewhere. This should be around the 5.8 ohm mark, a higher figure indicates a possible open circuit, and a lower figure may mean a winding is shorting out somewhere.
  
-Armature resistance: \\+**Armature resistance**: \\
 Placing one lead on a good, clean ground point on the case (shiny metal) and the other on the A terminal, will follow the path through the armature to ground. \\  Placing one lead on a good, clean ground point on the case (shiny metal) and the other on the A terminal, will follow the path through the armature to ground. \\ 
 This should be very low, typically less than 0.6 ohms but can vary as it depends on the brush/commutator condition. This should be very low, typically less than 0.6 ohms but can vary as it depends on the brush/commutator condition.
  
-Total resistance: \\+**Total resistance**: \\
 Placing the leads on a good ground point and the F terminal effectively measures the field plus armature circuits in series (from the F terminal, through the field windings, then through the armature to ground). \\ Placing the leads on a good ground point and the F terminal effectively measures the field plus armature circuits in series (from the F terminal, through the field windings, then through the armature to ground). \\
 As a quick check, this result should be very close to the values of the previous tests added together. As a quick check, this result should be very close to the values of the previous tests added together.
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 {{  :techtalk:ih:elec:generator_drawing_3_by_sifty.jpg?direct&400|}} {{  :techtalk:ih:elec:generator_drawing_3_by_sifty.jpg?direct&400|}}
-With the brushes out there are a couple of further tests available: ((photo by sifty of the XLFORUM http://xlforum.net/forums/showthread.php?t=1592463&page=42)) \\ +With the brushes out there are a couple of further tests available: ((photo by sifty of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/146604-first-harley-1975-xl1000-caf%C3%A9-project/page42?t=1592463&page=42)) \\ 
-Winding insulation: \\+**Winding insulation**: \\
 Placing one lead on a clean ground point of the casing, and the other on either terminal (do both) should give a very high reading (ideally in the Mega-ohms range). \\ Placing one lead on a clean ground point of the casing, and the other on either terminal (do both) should give a very high reading (ideally in the Mega-ohms range). \\
 This indicates the windings are not shorting to ground anywhere. This indicates the windings are not shorting to ground anywhere.
  
-Winding current: \\+**Winding current**: \\
 Connecting the battery through the multimeter in the Amps scale should result in a DC current of around 2 amps. \\  Connecting the battery through the multimeter in the Amps scale should result in a DC current of around 2 amps. \\ 
 Ohms law states V = IR, so with 12V and a resistance of around 6 ohms I = V/R which gives the 2 amps (will vary in practice as your winding resistance and battery voltage will differ). \\ Ohms law states V = IR, so with 12V and a resistance of around 6 ohms I = V/R which gives the 2 amps (will vary in practice as your winding resistance and battery voltage will differ). \\
  
-Motor test: \\+**Motor test**: \\
 This is probably the best indication, as a generator that will motor with voltage applied indicates all is well with the commutator / brush assembly. \\ This is probably the best indication, as a generator that will motor with voltage applied indicates all is well with the commutator / brush assembly. \\
 Jumper leads from a good battery were used and a short piece of wire (applied +12V to the A terminal, and -12V to the case and F terminal simultaneously). \\ Jumper leads from a good battery were used and a short piece of wire (applied +12V to the A terminal, and -12V to the case and F terminal simultaneously). \\

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