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No lights and Generator Adjustment

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Bill Soverns

03-04-2004 18:01:02




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Well Im almost there folks. New light switch installed on my WD 45 and the system is charging. I have rewired everything even the lights. When the new switch is placed in the middle position I still have no lights and this is driving me crazy! The bulbs are new. Am I missing a ground somewhere?

I also need to know how to adjust the generator. Its charging too much now. I looked in the owners manual but do not see any instructions on how to do so. Any help would be greatly appreciated.

Bill

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steve

03-04-2004 19:49:42




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 Re: No lights and Generator Adjustment in reply to Bill Soverns, 03-04-2004 18:01:02  
the light switch is a 3 position switch with a resistor on the back. the generator F terminal goes to one side of the resistor and the other side of resistor is grounded. with the light switch off, you get 2 amp charge because the resistor is in the F circuit to ground and drops the charge rate. with the light swithc pulled out there are two positions. one is "lights" and ground the "F" wire from the generator so you have a full 8 amp charge and the other position is ground the "F" and get 8 amps with no lights on. maybe you have the light wire on the wrong terminal, or the light case not grounded. on the back of the generator there is a small screw near the center shaft. you can loosen the screw, then rotate the third brush in teh generator to adjust the "charging" somewhat. I would not do that untill you run an hour and get the battery full charged and make sure your lights work and the ampmeter is accurate.

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Bill Soverns

03-05-2004 10:44:22




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 Re: Re: No lights and Generator Adjustment in reply to steve, 03-04-2004 19:49:42  
Thanks Steve. I now have working lights. Turned out to be bad ground. The inside of the lights were filthy and after cleaning them good the lights work just fine. I adjusted the generator down as far as I think I can. The ampmeter is still showing too much charge. Running about 7 on low and 15 on high. This is at about idle speed and when I open the throttle the charge goes up but I assume that is normal. Is that much extra voltage too much? Im thinking it is but Im not sure how to correct it. The ampmeter is old so Im thinking of replacing it.

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John McPherson

03-05-2004 13:09:29




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 Re: Re: Re: No lights and Generator Adjustment in reply to Bill Soverns, 03-05-2004 10:44:22  
The ammeter is likely only intended to give an approximate charge current anyway, so as long it is working, I would leave it.

If the battery is not fully charged, or corroded connections, or if there is a battery cell shorting out the current will remain high.

Normally that third brush is adjusted for maximum output, and you should have a cutout in the charging system if not an actual regulator. If either of these is present, the contacts might be fused, pitted and dirty or corroded- which while normally prevent a system from charging, they will also at times do the opposite too.

If battery is fully charged, you should see a charge rate about 1 to 2 volts above the battery voltage, and with engine running the current output from the generator should be about 5 to 7 amps. If the ignition coil is the wrong operating voltage, this can throw this reading off too. Say a 6 volt coil on a 12 volt system, or a 12 volt coil on a 6 volt system. Also if there is supposed to be a primary resistor in the ignition circuit and that is missing, can also register a higher current (this also burns the points too.)

from your description, what you are seeing may not be much of an issue, the system is working and unless you start burning out lights, generators, or ignition points, the meter may just be poorly calibrated.

If the generator does not heat up from running for a half hour, and the water level stays good on the battery, I would not change anything for now.

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Bill Soverns

03-05-2004 15:41:11




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 Re: Re: Re: Re: No lights and Generator Adjustment in reply to John McPherson, 03-05-2004 13:09:29  
Thanks for the advice. I ordered a new Ampmeter just in case. It was cheap so I figure no harm done. The cutout relay is brand new and it was designed for 6 volt along with everything else in the system. I will keep an eye on things for now until the new meter arrives. If things look the same after the new meter is installed I may just call it a day. Maybe Im being to picky.



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steve

03-05-2004 15:27:52




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 Re: Re: Re: Re: No lights and Generator Adjustment in reply to John McPherson, 03-05-2004 13:09:29  
yep.



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Bill Soverns

03-05-2004 16:11:50




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 Re: Re: Re: Re: Re: No lights and Generator Adjust in reply to steve, 03-05-2004 15:27:52  
ROFL - well okay then! I got this way because I've had nothing but trouble with the electrical system from day one. Guess I should relax and have a beer or two.



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