16.8. Generator

Elements of fastening of the generator
1 – adjusting bolt;
2 - generator 90 A;
3 – bolt, 20–25 N • m;
4 – bolt, 20–28 N • m;
5 – arm; 		6 – bolt, 12–15 N • m;
7 – bolt;
8 – generator 75 A;
9 – adjusting bolt;
10 – bolt, 20–25 N • m.

Removal

PERFORMANCE ORDER
1. Disconnect a wire from the negative plug of the rechargeable battery and sockets from the fan of a radiator and the fan of the condenser.
2. Turn out bolts of fastening of a radiator.
3. Weaken an adjusting bolt of a tension of a belt and turn out a bolt of fastening of the generator. Lift the car.
4. Disconnect the socket from the generator and a wire from the generator B+ plug.
5. Turn out a bolt and nuts of fastening of the generator. Lift a radiator and remove the generator from the car.

Dismantling (75 A)
Prevention

Establish soft protective overlays for an exception of damage of details of the generator on sponges of a vice.

PERFORMANCE ORDER
1. Fix the generator in a vice and turn out three coupling bolts.
2. Insert an edge of two flat screw-drivers between a forward cover and a magnetic conductor of the stator and uncover.
Prevention

Do not insert the screw-driver too deeply as it is possible to damage a stator winding.
The back cover can be removed hardly as the ring fixing an external ring of the back bearing is used. For simplification of removal of a back cover heat it the 200 W soldering iron. Do not use the hair dryer as it is possible to damage the block of diodes for heating.

3. Fix in a vice a rotor from a pulley.
4. Turn out a nut of fastening of a pulley, then remove a spring washer, a pulley and the expansion plug.
5. Remove a forward cover and two washers.
6. Remove a rotor from a vice.
7. Turn out screws of fastening of the brush holder, the rectifier and a nut of fastening of the plug B.
8. Remove the stator from a back cover.
9. Separate a maslootrazhatel from the brush holder.
10. Unsolder three wires from diodes and remove the stator.
Prevention

You see off Otpaivaniye during no more than 5 with as, otherwise, rectifier diodes can be damaged.

11. At separation of the rectifier from the brush holder unsolder two plates soldered to the rectifier.

Check (75 A)

Rotor
PERFORMANCE ORDER
1. Measure by an ohmmeter resistance between contact rings. If resistance extremely low, so is available short circuit in a rotor winding. If conductivity is absent, so there is a break in a rotor winding, at the same time it is necessary to replace a rotor.

Resistance: 3,1 Ohms

2. An ohmmeter check conductivity between a contact ring and an anchor of a rotor. With conductivity, replace a rotor.

Stator
PERFORMANCE ORDER
1. An ohmmeter check conductivity between stator coil wires. In the absence of conductivity replace the stator.
2. An ohmmeter check conductivity between stator coils. With conductivity, replace the stator.

Check of the block of the rectifier
PERFORMANCE ORDER
1. Check conductivity between positive poles of the rectifier and a clip of a conclusion of the coil of the stator. The ohmmeter has to show conductivity only in one direction. If conductivity is available in both directions, so the diode and the rectifier is punched it is necessary to replace.
2. Check conductivity between negative poles of the rectifier and a clip of a conclusion of the coil of the stator. The ohmmeter has to show conductivity only in one direction. If conductivity is available in both directions, so the diode and the rectifier is punched it is necessary to replace.
3. An ohmmeter check conductivity between conclusions of each of three diodes. The ohmmeter has to show conductivity only in one direction.
If conductivity is available in both directions, so the diode and the rectifier is punched it is necessary to replace.

Replacement of brushes
PERFORMANCE ORDER
1. If brushes are worn-out to maximum permissible length, replace them.
2. Unsolder a wattled wire and remove a spring and a brush.
3. Install a spring of a brush and a new brush in the brush holder.
4. Insert a brush so that there was a distance in 2–3 mm between the line of extreme wear and an end face of the brush holder.
5. Solder a wattled wire to the brush holder.

Dismantling (90 A)

PERFORMANCE ORDER
1. Turn out nuts of fastening of the plug "B" to a back cover.
2. If it is necessary to remove the stator, unsolder four wires of the stator from rectifier diodes.
Prevention

You see off Otpaivaniye during no more than 5 with as, otherwise, rectifier diodes can be damaged.

3. Remove the stator from a back cover.
4. Remove the brush holder and the rectifier.
5. Turn out four coupling bolts.
6. Insert an edge of two flat screw-drivers between a forward cover and a magnetic conductor of the stator and uncover.
Prevention

Do not insert the screw-driver too deeply as it is possible to damage a stator winding.
The back cover can be removed hardly as the ring fixing an external ring of the back bearing is used. For simplification of removal of a back cover heat it the 200 W soldering iron. Do not use the hair dryer as it is possible to damage the block of diodes for heating.

7. Fix in a vice a rotor from a pulley.
Prevention

Establish soft protective overlays for an exception of damage of details of the generator on sponges of a vice.

8. Turn out a nut of fastening of a pulley, then remove a spring washer, a pulley and the expansion plug.
9. Remove a forward cover and washers.
10. Remove a rotor from a vice.
11. At separation of the rectifier from the brush holder unsolder two plates from the rectifier.

Check (90 A)

Rotor
PERFORMANCE ORDER
1. Measure by an ohmmeter resistance between contact rings. If resistance extremely low, so is available short circuit in a rotor winding. If conductivity is absent, so there is a break in a rotor winding, at the same time it is necessary to replace a rotor.

Resistance: 3,1 Ohms

2. An ohmmeter check conductivity between a contact ring and an anchor of a rotor. With conductivity replace a rotor.

Stator

PERFORMANCE ORDER
1. An ohmmeter check conductivity between stator coil wires. In the absence of conductivity replace the stator.
2. An ohmmeter check conductivity between stator coils. With conductivity replace the stator.

Check of the block of the rectifier
PERFORMANCE ORDER
1. Check conductivity between positive poles of the rectifier and a clip of a conclusion of the coil of the stator. The ohmmeter has to show conductivity only in one direction. If conductivity is available in both directions, so the diode and the rectifier is punched it is necessary to replace.
2. Check conductivity between negative poles of the rectifier and a clip of a conclusion of the coil of the stator. The ohmmeter has to show conductivity only in one direction. If conductivity is available in both directions, so the diode and the rectifier is punched it is necessary to replace.
3. An ohmmeter check conductivity between conclusions of each of three diodes. The ohmmeter has to show conductivity only in one direction. If conductivity is available in both directions, so the diode and the rectifier is punched it is necessary to replace.

Assembly

PERFORMANCE ORDER
1. Assembly is carried out to the sequences, the return dismantling, taking into account the following.
2. Before accession of a rotor to a back cover insert a wire through a small opening in a back cover for fixing of brushes in the taken-away situation. After installation of a rotor get a wire.

Installation
PERFORMANCE ORDER
1. Install the generator on the engine. Insert the central bolt of fastening of the generator, but do not screw on it a nut.
2. Move the generator to one party on the central bolt of fastening of the generator and measure distance between a support of the generator and an arm.
3. Pick up set of expansion washers corresponding to the measured distance.
4. Insert expansion washers and screw a nut on the central bolt of fastening of the generator. Further installation is carried out to the sequences, the return to removal.