Re: [T3] generator issues continue...

["Jim Adney" <jadney@vwtype3.org>]

On 5 May 2008 at 9:35, Kevin Guarnotta wrote:

> A few posts have mentioned a small screw on the front end of the generator.
> The only screws I see are the following
> -two large head screws on either side of the generator
> -A small screw holding a ground wire in the middle of the generator.
> -a small screw holding down the black block with spade connectors.
> -small screws holding wires connecting to brushes

> -two screws that run through the whole generator holding it together.

You'll have to take the generator out, or use a mirror, to see that 
one little screw. Look at the end where the heads of the 2 long thru 
bolts are. There should be a little screw head visible in one of the 
cutouts in that end; it's recessed 1/4-3/8" below the surface. That's 
probably a good thing to check. If that screw is missing, then the 
generator could work if the 2 parts touch and won't work if they 
don't touch. If the screw is missing, you should be able to see the 2 
straps that the screw would have connected together. That screw could 
easily have been left out in their rebuild if they forgot about it 
when re-assembling.

It sounds like your shop actually does know what they're doing, but 
they don't see many generators any more, so it's not too surprising 
that they might have trouble finding the actual problem. The springs 
are probably okay, but the brushes need to slide easily in the brush 
guides and they can get bent when someone presses too hard on the 
pigtail screws. The guides may need to be bent back out a bit so that 
the brushes slide easily.

I had to file brushes down once to get them to fit right; if they are 
too long, the spring pushes sideways on them and they jam.

Other things to look for are the wires that solder to the underside 
of the DF & D+ terminals. Make sure they are still soldered there and 
haven't broken, and make sure that they're not rubbing against the 
thru bolts and shorting out.


-- 
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Jim Adney, jadney@vwtype3.org
Madison, Wisconsin, USA
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