7.2.7. Dismantling, check and assembly of the generator

Fig. 7.19. Generator components: 1 – pulley; 2 – sealing ring; 3 – rotor assembled; 4 – back bearing; 5 – holder of the bearing; 6 – forward arm of the generator; 7 – forward cover; 8 – stator; 9 – level; 10 – regulator of tension and brush holder; 11 – brush; 12 – brush spring; 13 – dustproof ring; 14 – vypryamitelny block; 15 – back arm of the generator



Dismantling (75 model And)
Turn off three coupling bolts.

Fig. 7.20. Removal of a forward kronshteyg of the generator


Insert the flat screw-driver between a forward arm of the generator and the stator and, working with the screw-driver as the lever, separate (down) a forward arm of the generator (fig. 7.20).

ATTENTION
Do not insert the screw-driver too deeply not to damage a stator winding.

Fig. 7.21. Heating of knot of the bearing by means of a soldering iron


It can turn out that it will be difficult to remove a back arm of the generator as stirs the lock ring used for fixing of the back bearing. For simplification of removal of a back arm warm up bearing knot by means of the 200 W soldering iron (fig. 7.21).

Do not use the thermal gun as in this case damage of vypryamitelny diodes is possible to heating.
Fix a rotor in a vice so that the party with a pulley was above.

ATTENTION
You watch that sponges of a vice did not damage a rotor.

Turn off a nut of fastening of a pulley, remove a spring washer, then remove a pulley and a pro-rate.
Remove a forward arm of the generator and two sealing rings.
Take a rotor from a vice.

Fig. 7.22. A conclusion nut detachment "In" the generator


Unscrew screws of fastening of the brush holder and the vypryamitelny block. Then turn off a conclusion nut "In" the generator (fig. 7.22).
Remove the stator assembled from a back arm.
Remove a dustproof ring from the brush holder.
Before removal of the stator unsolder three wires of a winding of the stator from the main diodes of the vypryamitelny block.

ATTENTION
At a soldering / raspayka of contacts, be careful that heat from a soldering iron influenced diodes as little as possible. You make these operations as soon as possible.
Be careful not to make excessive efforts for contacts of diodes.


Fig. 7.23. Places of the soldering of contacts of the brush holder


Before a detachment of the vypryamitelny block from the brush holder unsolder two contacts soldered to the vypryamitelny block (fig. 7.23).

Check of a rotor

Fig. 7.24. Verification of the closed chain between contact rings


Check lack of break in a rotor winding. Check existence of the closed chain between contact rings (fig. 7.24).
If resistance too little (aspires to 0), it demonstrates existence of short circuit. In case of break in a chain of a winding of a rotor or existence of short circuit replace a rotor assembled.
Resistance: about 3,1 Ohms.

Fig. 7.25. Check of lack of short circuit of a winding of a rotor on "weight"


Check lack of short circuit of a winding of a rotor for "weight" (fig. 7.25).
Check lack of the closed chain between a contact ring and the core. In case of existence of the closed chain (short circuit) replace a rotor with "weight" assembled.

Check of the stator
Check lack of break in a stator winding.

Fig. 7.26. Verification of the closed chain between stator winding conclusions


Check existence of the closed chain between stator winding conclusions. If the chain of a winding is opened (resistance strives for infinity), replace the stator assembled (fig. 7.26).

Fig. 7.27. Check of lack of short circuit of a winding on "weight"


Check lack of short circuit of a winding of the stator for "weight" (there is no closed chain between a winding of the stator and the core) (fig. 7.27).
If the chain is closed (resistance tends to zero), replace the stator.

Check of a positive conclusion of the vypryamitelny block

Fig. 7.28. Check of the closed chain between a conclusion of "positive" diodes of the vypryamitelny block and a conclusion of a winding of the stator


By means of an ohmmeter be convinced that the chain between a conclusion of "positive" diodes of the vypryamitelny block and a conclusion of a winding of the stator is closed (resistance a little). Change polarity of connection of samplers of an ohmmeter and measure resistance (if resistance a little, i.e. the chain is closed in both directions, the diode means it is punched) (fig. 7.28).
Replace the vypryamitelny block assembled.

Check of a negative conclusion of the vypryamitelny block

Fig. 7.29. Check of the closed chain between a conclusion of "negative" diodes of the vypryamitelny block and a conclusion of a winding of the stator


By means of an ohmmeter be convinced that the chain between a conclusion of "negative" diodes of the vypryamitelny block and a conclusion of a winding of the stator is closed (resistance a little). Change polarity of connection of samplers of an ohmmeter and measure resistance (if resistance a little, i.e. the chain is closed in both directions, the diode means it is punched) (fig. 7.29).
Replace the vypryamitelny block assembled.

Check of three diodes of the vypryamitelny block

Fig. 7.30. Check of diodes of the stator


Check three diodes, connecting an ohmmeter to both conclusions of each diode. For each diode the chain has to be closed only in one direction (fig. 7.30).
In the absence of the closed chain in both directions (or in the presence of the closed chain in both directions) the diode is faulty and the vypryamitelny block (heatdisseminating the block) is subject to replacement.

Replacement of brushes

Fig. 7.31. Limiting line of wear of a brush


Replace brushes if their wear reached a limiting line (fig. 7.31).

Fig. 7.32. Places of the soldering of wires


Unsolder a wire of a brush and take a generator brush with a spring (fig. 7.32).
Install a spring and a new brush in the brush holder.

Fig. 7.33. Scheme of installation of a brush


Insert a brush so that between edge of the brush holder and a limiting line on a brush made distance of 2-3 mm (fig. 7.33).
Solder a brush wire to the brush holder

Dismantling (90 model And)
Turn off a conclusion nut "In" the generator and remove a back cover.

Fig. 7.34. Places of the soldering of wires of a winding of the stator


Before removal of the stator unsolder four wires of a winding of the stator from the main diodes of the vypryamitelny block (fig. 7.34).

ATTENTION
At a soldering / raspayka of contacts be careful that heat from a soldering iron influenced diodes as little as possible. You make these operations as soon as possible.
Be careful not to make excessive efforts for contacts of diodes.

Remove the stator assembled from a back arm of the generator.
Remove the brush holder and the vypryamitelny block.
Turn off four coupling bolts.

Fig. 7.35. Removal of a forward kronshteyg of the generator


Insert the flat screw-driver between a forward arm of the generator and the stator and, working with the screw-driver as the lever, separate (down) a forward arm of the generator (fig. 7.35).

ATTENTION
Do not insert the screw-driver too deeply not to damage a stator winding.
It can turn out that it will be difficult to remove a back arm of the generator as stirs the lock ring used for fixing of the back bearing. For simplification of removal of a back arm warm up bearing knot by means of the 200 W soldering iron.
Do not use the thermal gun as in this case damage of vypryamitelny diodes is possible to heating.

Fix a rotor in a vice so that the party with a pulley was above.

ATTENTION
You watch that sponges of a vice did not damage a rotor.


Fig. 7.36. Removal of a pulley of the generator


Turn off a nut of fastening of a pulley, remove a spring washer, then a pulley and a pro-rate (fig. 7.36).
Remove a forward arm of the generator and sealing rings.
Take a rotor from a vice.

Fig. 7.37. Places of the soldering of contacts to the vypryamitelny block


Before a detachment of the vypryamitelny block from the brush holder unsolder two contacts (plate) soldered to the vypryamitelny block (fig. 7.37).

Check of a rotor

Fig. 7.38. Check of a chain between contact rings


Check lack of break in a rotor winding. Check existence of the closed chain between contact rings (fig. 7.38).
If resistance too little (aspires to 0), it demonstrates existence of short circuit. In case of break in a chain of a winding of a rotor or existence of short circuit replace a rotor assembled.
Resistance: about 3,1 Ohms.
Check lack of short circuit of a winding of a rotor for "weight".

Fig. 7.39. Check of lack of a chain between a contact ring and the core


Check lack of the closed chain between a contact ring and the core (fig. 7.39).
In case of existence of the closed chain (short circuit) replace a rotor with "weight" assembled.

Check of the stator

Fig. 7.40. Check of the closed chain between stator winding conclusions


Check lack of break in a stator winding. Check existence of the closed chain between conclusions of a winding of the stator (fig. 7.40).
If the chain of a winding is opened (resistance strives for infinity), then replace the stator assembled.

Fig. 7.41. Check of lack of short circuit of a winding of the stator on "weight"


Check lack of short circuit of a winding of the stator for "weight" (there is no closed chain between a winding of the stator and the core) (fig. 7.41).
If the chain is closed (resistance tends to zero), replace the stator assembled.

Check of a positive conclusion of the vypryamitelny block

Fig. 7.42. Check of the closed chain between a conclusion of "positive" diodes of the vypryamitelny block and a conclusion of a winding of the stator


By means of an ohmmeter be convinced that the chain between a conclusion of "positive" diodes of the vypryamitelny block and a conclusion of a winding of the stator is closed (resistance a little) (fig. 7.42).
Change polarity of connection of samplers of an ohmmeter and measure resistance (if resistance a little, i.e. the chain is closed in both directions, then the diode is punched). Replace the vypryamitelny block assembled.

Check of a negative conclusion of the vypryamitelny block

Fig. 7.43. Check of a negative conclusion of the vypryamitelny block


By means of an ohmmeter be convinced that the chain between a conclusion of "negative" diodes of the vypryamitelny block and a conclusion of a winding of the stator is closed (resistance a little) (fig. 7.43).
Change polarity of connection of samplers of an ohmmeter and measure resistance (if resistance a little, i.e. the chain is closed in both directions, then the diode is punched). Replace the vypryamitelny block assembled.

Check of three diodes of the vypryamitelny block

Fig. 7.44. Check of three diodes of the vypryamitelny block


Check three diodes, connecting an ohmmeter to both conclusions of each diode. For each diode the chain has to be closed only in one direction (fig. 7.44).
In the absence of the closed chain in both directions (or in the presence of the closed chain in both directions) the diode is faulty and the vypryamitelny block (heatdisseminating the block) is subject to replacement.

Assembly
Assembly is carried out as it should be, the return to dismantling. Pay attention to the following:

Fig. 7.45. Fixing of the lifted brushes


before installation of a rotor in a back arm, insert a thin wire into a small opening in an arm to record the lifted brushes (fig. 7.45). Take out a wire after installation of a rotor.

Installation
Install the generator into place and insert a bolt of hinged fastening (do not tighten a nut of a bolt of hinged fastening).

Fig. 7.46. Installation of the generator


Push the generator forward and define how many pro-rates (each 0,198 mm thick) it is necessary to insert between a forward rack of the generator and a forward cover of the engine (a gap "And" in the figure 7.46).
Pick up such quantity of pro-rates that they did not fall in attempt to insert them into a gap.

Fig. 7.47. The Vetilyatsionny opening in a cover of the rechargeable battery


Insert pro-rates (into a gap "And" in the figure 7.47), connect and tighten a nut of a bolt of hinged fastening for completion of installation.