Gege Blog 9.1 Dynamo Engine A (f) .pdf



Nom original: Gege_Blog_9.1_-Dynamo_Engine_A (f).PDF

Ce document au format PDF 1.7 a été généré par / pdfaid using ABCpdf, et a été envoyé sur fichier-pdf.fr le 15/06/2020 à 16:04, depuis l'adresse IP 78.146.x.x. La présente page de téléchargement du fichier a été vue 59 fois.
Taille du document: 4.4 Mo (41 pages).
Confidentialité: fichier public


Aperçu du document


1

Gege Blog English – 9.1 – DYNAMO Engine A - Dynamo "A"
Wednesday, February 6, 2013
Andre brought me a dynamo today, maybe the one that was on his car. Unlike the almost complete starter, this is not a "gift",
and illustrates the embarrassment of buying a car in parts in crates. Previous "restorers" have misplaced many parts ... See
here a poor-quality drawing (from the parts catalogue) , and without parts list (the same as for the starter)

M

IC
AL
E

5H
P

I present the pieces and try to figure out how it's put together, looking at the very incomplete drawing ..

G

VG

/A

The front flange with the brushes and the starting handle dog (called ” wolf's tooth” / Dent de Loup in French ) for the crank


There I placed the third thin and apparently new brush which was in a plastic bag. Two zamac brush holders are broken, we'll
have to find some more ... or make new ones!

2

/A

.

M

IC
AL
E

5H
P

. The same flange seen from the other side with the front bearing housing. The closing plate fixed by 4 screws is missing.

G

VG

The armature with on the left side of the picture an oil-thrower ring on the engine side, and on the right the shaft with the
hole to block the starter dog ... or the pulley (which we do not have !) for the fan drive.

3

5H
P

The rear flange into which a bearing is inserted

/A

M

IC
AL
E

Therefore, the dynamo drive plate must be removed from the end of the crankshaft to be able to install this bearing :

G

VG

once again, the parts drawing of the dynamo is totally lacking on this subject, this plate is mounted on the axis of the conical
armature with a key. And when you don't know it (like me), you try to pull it ... and it works! By the way, the nut was missing!

4

/A

M

IC
AL
E

5H
P

The parts in order

VG

I take the measurements for the bearings, 25x52x15 on the block side (so it's a 6205, we'll put a 6205-2RSH waterproof), and
15x42x13 on the brush side (so a 6302-2RSH waterproof).

G

The straps closing the holes to the brushes (dynamo and starter)

5

VG

/A

M

IC
AL
E

Last pictures : the wires that will be refilled with heat-shrink tubing:

5H
P

I position the flanges on the carcass to measure the overall length: 150 mm, it will be necessary to find or refabricate the 2
long screws and the 2 nuts which maintain the whole together:

G

In summary, and at first glance, are missing :

* the two bearings (No problem, it's standard!)
* 2 brush holders (1 big and 1 small) (OK, we bought them!)
* The closing plate of the front bearing (OK, Michel to be made)
* The fan drive pulley (OK, Michel to be made, with a new starter dog!)
* The nut at the end of the armature block side (OK, we found one!)
* The two screws (about 160 mm) and the 2 nuts that hold the flanges on the casing (OK, Michel has refabricated them!)
If not, Michel will rebuild all this (good luck for the brush holders!) (it's done, except the brush holders and the brushes bought
at Dépanoto...) , but photos and precise dimensions would be welcome

6
Sunday 10th February 2013

.

IC
AL
E

5H
P

Michel made the "two screws (about 160 mm) and the 2 nuts that hold the flanges on the carcass":

He even added an insulator ..."
Tuesday 12th February 2013

M

It's carnival time for the dynamo...

G

VG

/A

First of all, redo the M12x175 thread on the armature which was massacred by too much tightening, the thread looks like a
sawtooth, impossible to screw a nut on it (that's probably why it's missing!) :

I start with the thread file, in order to be able to engage a suitable die. Luckily, I manage to get the thread cleanly!

7

.

M

IC
AL
E

5H
P

I even find the the correct nut

/A

:

G

VG

Here's the armature, axes cleaned, armature woven and scraped between the lamellas.

8

5H
P

I also clean the starter dog (which we probably won't use), and the dynamo drive with its oil return screw:

VG

/A

M

IC
AL
E

at the moment the brush holder flange, doesn't carry much, we still have to order new brush holders:

G

The drive-side flange, with its bearing housing:

9

5H
P

I'm cleaning the casing.

/A

M

IC
AL
E

And I'm removing the insulation strips I'm going to replace

.

G

VG

I have unsoldered the lugs in order to sheathe the wires, and I place heat-shrink tubing on the orange tubing to hold it in place.

10

5H
P

as well as the very thin thermo sheath at the wire ends:

VG
G

there you go.

/A

M

IC
AL
E

Re-welding of the original lugs

:

11
Tomorrow I'm going to buy new bearings, and I'm waiting for Michel's screws and the brush holders, and the cover plate and
the fan pulley...

5H
P

Three coats of satin black paint on the casing, and that's it for today ...

IC
AL
E

. .

Tuesday 19th February 2013

G

VG

/A

M

I have insulated the (slightly stripped) wires connecting the field windings with (real) insulating cloth.

which I then coated with two-component Loctite glue..

. With the long screws, which are also insulated, there is no risk of a short circuit!

12

G

VG

/A

M

IC
AL
E

5H
P

I'm taking measurements of the starter dog, which turns out to be cut out of plumbing pipe!

So Michel will be able to make the new pulley with the starter dog tightened in it ...
Wednesday, February 20, 2013
Simple job, at first glance ... Replace the brush holders and brushes by remanufactured parts, a maximum of half an hour of
relaxed work on the table in the warmth of the house, I said to myself ... But it wasn't as easy as I thought!

13

5H
P

Presentation of the parts :

.

G

taking off the negative brush

VG

/A

M

IC
AL
E

Dismantling of the broken excitation brush holder

and so, on

14

5H
P

I unpack the brush holder kit which also includes the springs and the insulation washers, but not the screws to fix it on the
flange.

IC
AL
E

I had summarily cleaned the inside of the flange with petrol, it's disgusting..., I go down to the garage to clean all this properly
even if nobody will ever see it !

G

VG

/A

M

I'm going to take this opportunity to properly insulate the cable that goes from the positive brush to the + stud on the carcass,
otherwise the boss won't be happy ... Strangely, the cable shoe is soldered with tin on the nut, yet the nut and the thread are
intact. Maybe to avoid the wrong connection when disassembling/reassembling ?

I dismantle the two studs and their insulators...

,

15

G

Back to warmth, it's already less ugly.

VG

/A

M

IC
AL
E

and I put it back together, with a tin solder on the nut, as it was originally...

5H
P

I clean everything up and insulate the cable with heat-shrink tubing:

16

5H
P

I'm just about to rebuild it gently

G

VG

/A

M

IC
AL
E

but I notice that the brush holder + has foundry defects ? It is on this subject rather different from the other two, and was
packed separately.

17

5H
P

Moreover, some insulators do not fit in the holes provided, and the screws do not fit in some insulators. Back to the garage to
rectify all this with the Dremel, the file, the drill etc.!

:

VG

/A

M

IC
AL
E

From bottom
to top, the negative brush holder is impeccable, the positive is badly done but now rectified, and the excitation brush

G

The same from left to right. I filed the heads of 2 screws of the brush holders + (grounded because isolated from the +), which
seemed to pass close to the springs. I install them, but looking at the one in the middle, still the same badly melted (!), one
notices a defect in the notch of the spring, which prevented it from going down completely, hence again disassembling and
filing!

Well, it's finally done.

18

5H
P

,

IC
AL
E

but with this spring system, it's very difficult to wedge the brushes at the top to insert the armature. Swearing will rain again, I
can feel it!

G

.

VG

/A

M

I'm checking the insulation, no problem...

With all this delay, I'm too lazy to run the brushes on the armature surrounded by sandpaper (they are all flat, thanks
Depan...), I'll do it tomorrow!
Thursday 21 February 2013
Preparing the running-in of the brushes. The bearings are ready:

19

IC
AL
E

5H
P

This spring system is sadistic: no way to block them to lift the brushes in order to insert the armature. And impossible to insert
them from above, the springs are in the way. (Luckily, they put spiral springs on the traction dynamos, with that it's child's
play). Finally, I cut 3 steel strips to block them, but the brushes still protrude a little bit from the brush holders which are flush
with the commutator.

G

VG

/A

M

I fix some emery cloth on the commutator, and I manage with difficulty (especially with the thickness of the cloth) to slide the
armature.

Now , it's a bit run in, but it's going to be something ese to reintroduce the armature when the flange will be kept close to the
frame by the wires of the windings. Also I still don't know if the long wire goes to the + pin or to the excitation brush, and vice
versa for the short one.
Has anyone ever dismantled such a dynamo before?

5H
P

20

In the meantime, Michel made the cover holding the front bearing based on my measurements and photos from the 5HP
forum.

G

VG

/A

M

IC
AL
E

.

.
…beautiful, I'm looking forward to it

5H
P

21

IC
AL
E

Friday, February 22nd, 2013

“Michel LR539” * gave me the phone number of a specialist of old dynamos, information that he found on ... the 5HP site!
Thank you, Michel , the “GMT forumists”* are the most efficient, even when it is not about traction ...

G

VG

/A

M

But before annoying this specialist, I present the brush holder flange on the frame, and I realize that it would be difficult to
connect the "short" wire of the windings on the + stud. So I plug it on the excitation brush, and the long one on the + stud. Not
easy at all to do, but it's done




“Michel LR539” : a friend whose Traction is registered LR539
““GMT forumists”: members of Traction Avant forum

22

I managed to block the springs with small steel blades of the right width, bent at right angles.
… the positive brush

IC
AL
E

5H
P

Here is the excitation brush

/A

M

and the grounded brush

VG

.

G

I don't have the long screws yet that hold all this stuff together, but as the flanges are stuck a little bit in the carcass, it's
holding together pretty well, and I'm already rebuilding it temporarily.

.

23

5H
P

I'm inserting the armature

VG

/A

M

IC
AL
E

then bearing 6302 in the front brush holder flange

G

At the rear, the conical shaft with its keyway

24

5H
P

I place the flange with its 6205-bearing flush and lock the small screw of the external cage.

,

.

G

VG

/A

M

IC
AL
E

… then I introduce the "fork" with its oil-thrower ring, and I temporarily place the nut which will be replaced by a lowered nut
plus a grower washer or "fan " ?? washer (did they exist in 1924?).

This fork fits into a washer with 4 notches at the end of the crankshaft (here at the disassembly):

)

25

5H
P

Everything is more or less held together, I take out the spring holding plates, I place a small connection between the + and X
pads.

.

VG

/A

M

IC
AL
E

Instant of truth, I test the dynamo with the multimeter by turning it by hand, and it comes out ... 18 mV. (Couldn't get the
picture as it was producing such a voltage! , only 8mV here )

G

At this speed, it's not bad, and so I think it's functional! Moreover, by turning it in the good direction, it flows well positively,
my connections are correct ...

26

5H
P

And here is the schematic of this Citroën dynamo with 3 brushes:

( Click to get enlarged image )

G

VG

/A

M

IC
AL
E

Strangely, the old 5HP general wiring schematics mention to ground the X connector

( Click to get enlarged image )

27

IC
AL
E

5H
P

As there is no detail of the internal connections, it's difficult to get an idea, but in any case, it wouldn't work with this dynamo
as it is connected! Moreover, it is not specified how the circuit breaker on the dynamo is connected. A member of the 5HP
forum posted a corrected schematic with the shunt between the X and + external studs:

( Click to get enlarged image )

G

VG

/A

M

And to be complete, a double general schematic, where we can see the internal connection of the dynamo used in the first
5HP assembly with battery ignition, coil and distributor:

( Click to get enlarged image )

28
I'm now waiting for the screws, the cover and the pulley with the starter dog to complete this reconstruction. Ah yes, I would
also have to look at the circuit breaker ...
(PS: I found the supreme punishment for the 5HPist not wise: change the brushes at the roadside, dynamo in place, at night
and in the rain ...)

Monday 25 February 2013

G

VG

/A

M

IC
AL
E

5H
P

Received this morning the parts made by Michel. I'm not going to praise him again, but it's... perfect! It's amazing what you
can do at a distance of 2000 km: in Bruxelles I take the measurements under his instructions (my calliper is getting seriously
hot), and I see on one of my (3) screens the shot he's making live on Autocad in Italy ... If necessary, I turn on my camera so
that he can visualize the parts on which the new ones are to be mounted. We also use photos gleaned here and there, but
Michel's realisations are more beautiful (only the chevrons are missing, but I wouldn't be surprised if he puts one up one of
these days!). Just for the long screws, we have scrupulously measured the cone (30°) so that the head fits perfectly into the
flange ... And the small ones holding the lid are special with their non-standard thread of 5 with a pitch of 0.75 (instead of
0.80)...

Of course, the front bearing cover fits perfectly ..

29

5H
P

The starter dog made of plumbing pipe comes in, but it will be remade in a serious and rigorous way.

G

VG

/A

M

IC
AL
E

I go down to the garage in order to increase the hole in the shaft of the armature with a drill bit of 6, and cut the screws
voluntarily too long in case we were mistaken .

30

5H
P

The distance between the end of the hole and the bearing is 14 mm (not easy to photograph). As it's the starter dog that
blocks the armature, no room for error ...

G

VG

/A

M

IC
AL
E

In order to test the dynamo in motor, I temporarily place a 6mm screw. I had to rectify the hole in this bad “wolf tooth,” it is
badly drilled . And the holes didn't match (that's why there was a funny pin too thin and twisted), I had to seriously file its end.
Another example of s... y "repair" , these cars had to run whatever the cost, and the mechanics didn't care about any quality
of work. Moreover, its inner diameter is 15.5 mm for an axle diameter of 14.5 mm... Appalling!

I fit the long screws cut to the right length, with their insulation (improvement compared to the original).

5H
P

31

G

VG

/A

M

IC
AL
E

It's time to test it in engine: pictures at 1/50th of a second, it's running (of course!)

.

Only the new starter dog and the pulley are missing ; coming soon...
Wednesday 27th February 2013
Here is the complete plan of the dynamo, which allowed to specify the exact position of the pulley so that it is just in line with
the fan. The pulley will be tightly mounted by 3 screws on a new wolf tooth perfectly adjusted on the shaft, and correctly
blocking the armature in the bearing.

32

5H
P

The starter dog is already machined, only the pulley remains ...

IC
AL
E

Thursday 28th February 2013

VG

/A

M

The pulley is turned, and placed on the starter dog for checking. It remains to make the housings for the 3 screws that will hold

G

it in place, as well as the corresponding notches on the starter dog ...

IC
AL
E

5H
P

33

Saturday 02 March 2013

G

VG

/A

M

And here we are: the pulley with its locking screws (we had thought of using Allen screws, it would have been more elegant
but anachronistic since they only appeared in 1943 ...), the starter dog with its locking pin (which will be covered by the pulley)
and the 120° indentations for the screws, and washers to take up any play.

Michel has even provided markers to facilitate the assembly ...

The parts will leave on Monday by mail, I'm waiting for them impatiently.

IC
AL
E

Wednesday 6th March 2013

5H
P

34

Monday, March 11, 2013

G

VG

/A

M

I had the armature collector rectified in a workshop in Brussels. Indeed there was a slight hollow in the center of the
commutator, and moreover its "edge" passed, to my taste, very close to the brush holders (they are perhaps slightly thicker
than the original ones). Now it's all good, and I'm waiting (still impatiently !) for Michel's parts ...

I received the package at lunchtime! Michel has even provided some dotted lines to cut out the packaging of the box, so that it
can be used again....

35

M

IC
AL
E

5H
P

. Unpacking, Michel has provided washers of different thicknesses to perfectly wedge the front bearing under the lid, a
massive steel axle of 6mm diameter to block the starter dog on the armature, and despite everything, elastic pins if we were a
hundredth wrong in our measurements ..

G

VG

/A

He even offers me a 0-25 mm micrometer, mine being 25-50!

I present the parts in front of the armature, it's the moment of truth. The starter dog is 14.55 mm inside diameter, and the
shaft of the armature is 14.5 mm. This must fit almost without play, so as not to have the disastrous results we saw with a
starter dog made of plumbing pipe, when the "mechanics" did everything they could with the means on board to make these
old cars run. Moreover, it's the starter dog that blocks the armature in the bearing, so the hole has to coincide to the
hundredth with the hole of the armature axle that I carefully drilled at 6 mm.

36

/A

M

IC
AL
E

I place the 15x42x13 (6302 RSH) bearing against its shoulder on the armature.

5H
P

.

G

VG

The new starter dog is made of steel, 24 mm outside diameter, except where it fits into the lid (see plan), it's strong! Its front
end is bored to 16 mm to let the crank handle in. I push it all the way against the bearing, and it's perfect: the two holes
coincide exactly! .

.
I put the massive 6mm axle, a small hammer stroke and nothing moves anymore (except the outer cage of the bearing which
rotates of course ...).

5H
P

37

G

VG

/A

M

IC
AL
E

Then I put on the aluminium pulley that covers the shaft, no danger that this one will escape !

Since everything is perfect, I take it apart again and put the bare armature into the casing. The bearing is firmly blocked behind
the flange cap, not “a hair” of play: .

.
I put the starter dog and its locking pin in place.

38

5H
P

,

/A

M

IC
AL
E

one swipe of the mallet and you're done:

.

G

VG

Then the pulley

Its rear recess comes 1 mm from the screw heads of the cover, and will be exactly in line with the fan pulley, the axis of the
groove being 80 mm from the lower edge of the distribution housing on the motor (see plan).

39

G

VG

/A

M

IC
AL
E

5H
P

Its exact longitudinal position is marked by partial drillings in the starter dog, in which the 120° screws that lock it are
positioned.

A rational and efficient assembly, not “a hair” of play!

5H
P

40

This dynamo comes back from far away ...
Friday 15 March 2013

IC
AL
E

Final work: I find that the tightness of the bearings in their housings and on the armature shaft is weak. Indeed, these parts
have been quite oxidized and then pickled. So I reassembled the bearings with Loctite 641, "Recommended for fixing parts
that will have to be disassembled, such as the bearings mounted on the shafts (and in their housings)", and here is the data
sheet.

G

VG

/A

M

Loctite 641, "

With these precautions, no more danger ...
I also made the shunt between the + and X studs, in a 1mm thick copper plate:

5H
P

41

IC
AL
E

All that's left to do is to strip and repaint the "strap" closing the apertures to the brushes ...

G

VG

/A

M

THE END


Aperçu du document Gege_Blog_9.1_-Dynamo_Engine_A (f).PDF - page 1/41
 
Gege_Blog_9.1_-Dynamo_Engine_A (f).PDF - page 2/41
Gege_Blog_9.1_-Dynamo_Engine_A (f).PDF - page 3/41
Gege_Blog_9.1_-Dynamo_Engine_A (f).PDF - page 4/41
Gege_Blog_9.1_-Dynamo_Engine_A (f).PDF - page 5/41
Gege_Blog_9.1_-Dynamo_Engine_A (f).PDF - page 6/41
 




Télécharger le fichier (PDF)


Gege_Blog_9.1_-Dynamo_Engine_A (f).PDF (PDF, 4.4 Mo)

Télécharger
Formats alternatifs: ZIP



Documents similaires


gegeblog91 dynamoenginea f
gegeblog101 starterenginea f
0686 05a
alternator regulator bosch
electrical
gegeblog111 engineaisbackfromitaly f