Undercutting Commutator Mica

After undercutting is completed, again smooth commutator with No. 00 sandpaper. It is also advisable to repeat "growler" check for "short" as there is a possibility of developing a "short" during the turning and undercutting operations. If so, it can very likely be corrected by more thorough cleaning between segments and at ends of commutator.

Reassembling Generator

(To Identify Items, Refer to IUus. 79 or 80)

1. If one or both field coils have to be reassembled, do this first. Remember that field coils (13) and (17) are not alike and must not be interchanged. If one has to be replaced, be sure it is replaced with one of same type.

Thoroughly clean generator frame where pole shoe seats and also clean face of pole shoe that seats against frame. Tighten pole shoe screws (9) and (11) as tight as possible, with a large screwdriver that fits well into screw slot. Unless screws are very tight, there will not be the required clearance (.007" or more) between armature and each pole shoe (this clearance is to be checked later when armature is assembled into frame).

2. Proceed with further assembly of generator.

reversing order of disassembly as outlined under "Disassembling 'Generator," Page 99.

3. If felt oil retaining washer (7), or oil seal explained in paragraph 11, under "Disassembling Generator," Page 99, is worn, renew it.

4. Thoroughly wash and closely inspect both the drive end and commutator end bearings, (5) and (42). If either is found worn to any extent, or pitted and rough, renew it. The commutator end bearing particularly should be replaced if it shows any appreciable wear, as a loose bearing allows commutator to run eccentric and chatter, even though commutator itself is perfectly true. Pack both bearings with high melting point grease (Harley-Davidson grade "A" grease).

5. Gauging Armature Pole Shoe Clearance-.

Select a sheet of paper .007" thick or use a double sheet totaling this thickness. Cut a piece as wide as length of armature core and long enough to wrap nearly, but not quite, around armature.

Assemble armature in frame with this paper around it, inserting shaft through drive end bearing. If pole shoe clearance is up to the required .007" or more on each side, armature can be inserted and will turn freely. If it binds, pole shoe or shoes removed and replaced must be pulled tighter to frame with pole shoe screws. Possibly parts were not well cleaned and there are particles of dirt between shoe and frame, preventing full seating.

Specified pole shoe clearance is necessary to allow for expansion of armature when hot and for play that normally develops due to bearing wear. Taking a chance on less than specified clearance may result in armature striking pole shoe and damaging both the armature and pole shoe. An armature damaged in this manner is usually grounded and must be renewed.

6. Installing Frame End: Generator frame end fits over register in frame and is located by a dowel pin in frame and a corresponding hole in frame end. Frame end must be a snug fit on frame register or a new end must be installed. If frame end is loose on frame, armature-pole shoe clearance is affected and the likely result is a damaged armature. Tighten screws securely.

7. Complete assembly of generator. Be sure pin that secures drive gear, oil centrifuge or spring collar is well riveted at both ends to prevent it from coming out in service and causing serious damage to timing gears and other parts. Side Valve Engine only: Measure the distance from outer face of oil centrifuge on end of armature shaft to end of generator frame (gasket removed). This distance should be 1-53/64" to 1-27/32". Adjust if necessary by removing or adding an armature spacer (18).

Connect field coil wires according to Illus. 96 or 97 and paragraph "2" under "Disassembling Generator," Page 99.

Test generator on test stand if this equipment is available. If not, install on engine and test. Generator output can be adjusted as follows: Three brush generator—by moving third brush; two brush generator— by adjusting current and voltage regulator. See "Generator Charging Rate."

Assembling Generator to Engine

Reverse the operations followed in "Removing Generator," Page 97; also refer to "Installing Generator," Page 64.

Make sure same number of paper shims are used in reassembling as were found underneath generator when it was removed. After an engine has seen considerable service and gears have worn to some extent, they have possibly developed enough lash or play to permit safely removing one or more of the original shims and thus effecting closer meshing and guieter operation. However, this should not be done unless timing gear case cover is removed so gear mesh and lash can be carefully checked.

Make sure all external wire connections are correct and tight.

Generator Charging Rate

(The following maximum rates specified are battery charge over eguipment loads indicated, which do not include sidecar lighting, using test ammeter at battery ground.)

1. Standard Generator:

A maximum charging rate of about 4 amperes with standard eguipment tail lamp, speedometer light and headlamp lighted (headlamp on upper light beam) is standard factory setting.

Radio Three Brush Generator:

A maximum charging rate of about 2 amperes with radio and standard eguipment tail lamp, speedometer

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