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F O R E W O R D
This booklet is intended primarily for the small service station owner and mechanic
who, though n o t normally concerned w i t h car " electrics,"
Generator (Part 1,
Test 1).
'~F/1063/L
Printed in England
1N
DEX
OF
SYSTEMATIC
FAULT
LOCATION
PROCEDURE
PART 1
PART 2
PART 3
PART 4
Regulator Tests:
Regulator Tests:
Regulator Tests:
C39PV
C42
C39Q
C45PV-5
C40A
C45PV-6
C40/1
C45PVS-6
C4OAL
C47
C40L
C48
Pages 5 - 9
Pages 10 - 16
Pages 17 - 26
C4OLQ
Pages 3 - 4
OPrinted i n England
No part of this book may be reproduced without permission.
JOSEPH
LUCAS
(EXPORT)
LTD.
46
PARK STREET
L O N D O N
W.1.
The following tests should be carried out with a good quality Moving Coil Voltmeter. The meter should have a full scale
deflection o f at least 20 volts, with divisions suitable for taking readings t o within 0.5 of a volt. A meter o f this standard will
be suitable for both 6 and 12-volt LUCAS equipped cars, trucks, etc., and 6 volt systems on motor cycles.
TEST 1.
Disconnect leads from generator.
Connect one lead of voltmeter t o D
terminal and the other t o a good
ground.
Start engine and raise speed until
generator is running at approx.
3,000 revlmin.
When vehicle has a positive ground
system positive meter lead must be
grounded.
READING
ACTION
A.
B.
Zero volts.
C.
Internal short between D and F terminals, examine field coils and rectify
as necessary o r fit replacement.
VOLTMETER CONNECTION
TEST 2.
Connect meter as i n Test 1.
Link terminals D and F on generator.
Gradually speed up engine t o fast
"tick-over" speed. If an ammeter
is used t o link D and F, reading
should not be more than* 2 amps,
when normal voltage o f system i s
registered on voltmeter.
"2.5 for C42 w i t h 43 ohm field.
READING
ACTION
A.
B.
C.
Z e r o volts.
TEST 3.
Reconnect leads o f generator.
Remove leads from D and F terminals
at the control box.
Connect one side o f voltmeter t o end
o f D lead, the other t o a good
ground, speed generator up t o
approx. 3,000 rev/min.
B.
Z e r o volts.
C.
TEST 4.
Leave voltmeter connected as i n Test 3.
Join D and F wires together.
Gradually speed up engine t o fast
"tick-over" speed.
A.
B.
Z e r o volts.
Earthed F lead.
C.
BART 2
M O D E L LRT9 R E G U L A T O R - SINGLE C O N T A C T 2 B O B B I N TYPE
(Used with RF95, 96, RB106/1, MCRZ, etc.)
READING
ACTION
I
TEST 5.
Reconnect generator leads t o control
box terminals D and F.
Connect one lead of voltmeter t o terminal A, the other t o terminal E on
the control box. Engine stationary.
A.
Battery voltage.
B.
ACTION
READING
VOLTMETER CONNECTION
TEST 6.
Proceed t o check regulator setting.
Remove control box cover.
Isolate the battery by placing a piece o f
d r y card between cut-out contacts,
alternatively, remove 'A' and A1
cables from terminals and join
together temporarily.
Connect one lead of voltmeter t o terminal D (or frame of regulator) and
the other lead t o a good ground.
--
A.
Temp.
O"
20C 68F
O
'' F)
6 volt Equip.
8.0-8-5
Regulator in order.
Proceed t o Test 7.
12 volt Equip.
16.0-1 6.5
B.
C.
Check ' D ' and ' F ' leads for shortcircuit, i f O.K. suspect broken shunt
winding i n regulator bobbin. The
ground lead from control box terminal E is common t o both shunt
windings (regulator and cut-out).
Hold a screwdriver near t o p o f the
bobbins and test for magnetic pull.
If there is pull o n the one bobbin
core and not on the other suspect
open circuit on the latter. If no pull on
either checkforopen circuited ground
lead. Replace defective regulator.
-.
VOLTMETER CONNECTION
ACTION
READING
TEST 6 (continued).
D.
I
ARMATURE
FIXING SCREWS
REGULATOR
/i
FRAME
E.
FIXED CONTACT
BRACKET
0.006'~0.017"
W I T H ARMATURE
PRESSED TO CORE
Diagram 1.
VOLTMETER CONNECTION
READING
ACTION
ALTERNATIVE COPPER
SEPARATION ON
B O B B I N CORE
ARMATURE ASSEMBLY
SECURING SCRiWSz&
'
m-!i.:
IDfi.
FIXED COPUTACT
I
'
ADJUSTMEl\T
DISC
SCRE'N
CORE
%urn
TWO WIPE,
TYPE OF SEPAPATION
DISC OR TWO W I W -
ARMATURE
/
- -0.015'
AND
WPPFR
SEPAR4TION
Diagram 2.
TEST 7.
Remove card from between cut-out
contacts.
Connect voltmeter t o terminal A on
control box and a good ground.
Engine stationary.
Battery voltage.
TEST 8.
Leaving voltmeter connected as for
Test 7. Start engine and watch
voltmeter.
A.
B.
VOLTMETER CONNECTION
TEST 9.
Connect one lead of voltmeter t o D
terminal of regulator or t o the regulator frame itself.
Other voltmeter lead t o agood ground.
READING
A.
6.3-6-7
ACTION
12 volt
12.7-1 3.3
6.
C.
PART 3
MODEL RB310 REGULATOR-
SINGLE C O N T A C T 3 B O B B I N TYPE
I t is important therefore, that the Model o f the generator is carefully noted before commencing the tests. This is
fernperature C o r r e c t i o n Factor
Corrections t o be made t o the open-circuit voltage limits when checking o r adjusting settings at temperatures other
than 20C (68F) are as follows:For every 10C (18F) above 20C,, subtract
0.1 volt f r o m the 6-volt limits
0.2 volt from the 12-volt limits
Conversely, the same corrections must be added for every 10C below 20C.
For generator tests, repeat Tests 1 - 4, o f Part 1, then proceed t o Test 5, o n page 11.
page 1 0
AMMETER CONNECTION
i;
~
I
~:
1
READING
A.
I
I
11I
ACTION
AMMETER CONNECTION
READING
TEST 5 (continued).
C.
CURRENT REGULATOR
FIXED CONTAC?
ADJUSTMENT
ARMATbRE ASSEMBLY
SECURiPIG SCREWS
TENSION
SPRING
_
CURRENT A ~ J U S T M E N T SCREW
AND
LOCKING
NUT
ALTERNATIVE COPPER
SEPARATION O N
DISC
SQUARE
ARMATURE
F-T
SEPARATION
GI\UGE
DlSC
SQUARE
Diagram 3.
page I 2
ACTION
VOLTMETER CONNECTION
READING
A.
ACTION
6 volt C/Box
Regulator in order.
Proceed t o Test 7.
I 2 volt C/Box
VOLTAGE REGULATOR
~
ARMATURE
ASSEMBLY
(REAR VIEW)
ALTERNATIVE COPPER
SEPARATION ON
B O B B I N CORE
DISC
I')
SQUARE
i.1
B.
C.
0 I - METAL
BRIGHT U N P L A T E D A
OR COPPER PLATED (
)
6)
ARMATURE
Diagram 4.
page I 3
VOLTMETER CONNECTION
READING
--
TEST 6 (continued).
BOBBIN
CORE
FIXED CONTACT
ADJUSTMENT
URE ASSEMBLY
-TENSION
SPRING
ACTION
Check ' D ' and F ' leads for shortcircuit, if O.K. suspect broken shunt
winding i n regulator bobbin. Shunt
windings o n both voltage regulator
and cut-out bobbins are t o common
earth. Hold a screwdriver near top
of voltage and cut-out bobbins and
test for magnetic pull.
If no pull check for open circuited
ground !ead o r shunt winding.
If defective fit replacement regulator.
TEST 7.
Battery Voltage.
VOLTMETER CONNECTION
TEST 8.
ACTION
TEST 9.
READING
--
Cut-out is in order.
Proceed t o Test 9.
B.
A.
6 volt
6.3-6.7
12 volt
12-7-1 3-3
B.
C.
AMMETER CONNECTION
READING
ACTION
METRIC EQUIVALENTS
mm.
0.005" = 0.127 m m.
0.006" = 0-152 rnrn.
0.01 0" = 0.25 mm.
0-015" = 0.396 mm.
0.020" = 0-51 m rn.
0.025" = 0.635 mm.
page 16
PART 4
M O D E L RB340 R E G U L A T O R - S I N G L E
C O N T A C T 3 BOBBIN TYPE
Conversely, the same corrections must be added for every 10C below 20C
For generator tests, repeat Tests 1 - 4, o f Part
READING
AMMETER CONNECTION
A.
ACTION
SHORT CIRCUITING~
V R CONTACTS.
- --
B.
page 18
AMMETER CONNECTION
TEST 5 (continued).
ACTION
READING
1
I
C.
CLIP
CURRENT REGULATOR
VOLTAGE REGULATOR
page 19
VOLTMETER CONNECTION
ACTION
READING
10C
20C
30C
40C
(50F)
(68F)
(86F)
(104F)
Setting
V R AND C.R
ARMATURE TO BOBBIN CORE GAP
0.045" 0 - 0 4 9 "
,,I
'\
CONTACT ADJUSTMENT
page 20
Proceed
VOLTMETER CONNECT1ON
READING
TEST 6 (continued)
ACTION
-
B.
C.
,- - - - - - - - - - - - - -.
- - -.
.
.
.
.
.
-- -.
.
D. V o l t m e t e r r e a d i n g
fluctuates, i.e.,
pointer fluctuating
m o r e t h a n 0.3-volt.
I , z::
;
I
t-
...
RELAY
"E"
--
--_I
VOLTAGE
REGULATOR
..I_.
- - - - -.: - - - - - - - - - - - - - - D
a.vL
-N
U N T i L EARL? i N 1962, THE VR. I CR MLGNLI F W E S WERE LINKED BY A CONNECTOR THROUGH WHICH
(IN THE CONTACTS CLOSE0 P O S I T I @ Y ) T H E
WINDINGS, TO TERMINAI'D:
FlELD
CR
SERIES
page
21
- -
READING
VOLTMETER C O N N E C T I O N
ACTION
TEST 6 (continued)
D. (continued)
TEST 7.
W i t h engine stationary. Reconnect
leads t o B-B terminal o n control box.
Connect voltmeter between B-B terminal and ground.
Battery voltage.
TEST 8.
A.
Cut-out is in order.
B.
page 22
Proceed t o Test 9.
VOLTMETER CONNECTION
READING
ACTION
---
- -- - -
A.
Cut-out i s in order.
Check, Test 10.
B.
C.
CUT- OUT
page 23
Proceed t o Final
VOLTMETER CONNECTION
READING
A.
B.
Adjust Drop-off volts as follows :Stop engine, and adjust the drop-off
voltage by carefully bending the fixed
contact bracket. Reducing the contact gap w i l l raise the drop-off
voltage; increasing the gap w i l l lower
the drop-off voltage.
Re-test and, if necessary, readjust until
the correct drop-off setting is
obtained.
Note: W h e n drop-off voltage is correct
the moving contact blade should
have a 'follow through' o r blade
deflection o f 0.010" - 0.020".
The armature back stop, when free,
should give a core gap o f 0.035"
- 0.045", adjust by bending stop w i t h
a suitable tool.
PHOSPHOR BRONZE
HINGE SPRING
ARMATURE
BLADE
FOLLOW-THROUGH'
'B%'TERMINAL
0.010'-0.020")
PLATE
ACTION
/ CONTROL
\
FIXED CONTACT
BRACKET
page 24
RB340 DESIGN
RESISTOR VALUES
(i) Contacts Resistor :
Resistance
in Ohms
37- 43
55 - 65
SWAMP RESISTOR
DATA
FIELD PARALLLL
RESISTOR
(WHEN FITTED)
'8-13'TERM I N A L
PLATE
zB-
8'
,F'
(12-volt units)
'WL: 'D'
'E'
i
page 25
RESISTANCE OF SHUNT
WINDINGS a t 20C (68F)
Voltage
Regulator: 10-8-12-0 ohms
Cut-out : 8.8 - 9.6 ohms
ADJUSTMENT CAMS
Torque to
turn cams : 2 - 4 Ib. in.
(0.023 - 0.046 kg m.)
Length
0-030" - 0.035"
(0.76 - 0.9 mm.)
Armature-to-bobbin core,
VR and CR :
0.045" - 0.049"
(1.04 - 1-24 m m.)
Armature-to-bobbin core,
Cut-out relay :
0.035" - 0.045"
(0.9 - 1.04 mm.)
'Follow-through'or blade
deflection of cut-out reiay
moving contact :
CONTACT
REPLACEMENT
(ii)
(iii)
Cut-out relay
armature :
Voltage regulator
armature :
Current regulator
armature :
(iii)
(iv)
(v)
(vi)
Insert a 0,045 (1.04 mm.) feeler gauge in the armature-tobobbin core gap as far back as the t w o tension spring rivets.
(vii)
(ix)
ADJUSTMENT SEQUENCE
After fitting a replacement contact set (or sets), the regulator o r
cut-out relay concerned must be adjusted both mechanically and
electrically. The order of electrical settings (when all three armatures have been replaced) being, first, the voltage regulator, secondly
the cut-out relay and, thirdly, the current regulator.
(ii)
(viii)
SETS
page 26