10.5.4. Generator repair

It be required to you: face heads «on 7» and TORX E8, a vorotok, a screw-driver with a flat edge, a soldering iron, a tester, a stripper and opravka for replacement of bearings of a rotor.

1. Remove the generator from the car (see. «Removal and generator installation»).

2. Turn out three screws of fastening of a plastic casing of the generator...	3.... also remove a casing.

4. Otpayayte a conclusion of shchetochny knot from a conclusion of a regulator of tension.	5. A face head «on 7» turn out two bolts of fastening of shchetochny knot to a back cover of the generator...

6.... also remove shchetochny knot.	7. Check a vystupaniye of brushes in a free condition. If the size H appears less than 2 mm replace brushes or shchetochny knot assembled. Check ease of moving of brushes in a shchetkoderzhatel. If they подклинивают, it is also necessary to replace shchetochny knot.

8. For replacement of brushes wring out three clamps of a cover of a shchetkoderzhatel...	9.... uncover...

10.... also take out brushes from a shchetkoderzhatel.

Note So generator brushes look. For replacement get just the same brushes.

11. Check a tester resistance of a winding of a rotor, having connected it to contact rings. Resistance should make about 3-5 Ohm. If indications on a tester show infinity, means, in a rotor winding and it it is necessary to replace break.	12. Check absence of short circuit of a winding of a rotor on the case, having connected tester conclusions to any contact ring and the rotor case. Indications of a tester should show infinity.

13. Check diodes of the vypryamitelny block. For this purpose establish a tester in a mode of measurement of resistance and connect "negative" (black) щуп a tester to a conclusion "plus" the generator, and "positive" (red) щуп serially connect to six contact conclusions of diodes. If diodes are serviceable, the tester will show resistance of 550-600 Ohm.	14. Connect "positive" (red) щуп a tester to a conclusion "plus" the generator, and "negative" (black) щуп serially connect to the same six contact conclusions of diodes. If diodes are serviceable, the tester will show infinitely big resistance.

15. For check of additional diodes connect "positive" (red) щуп a tester to conclusions of a winding of a stator to which conclusions of additional diodes are soldered, and "negative" (black) щуп connect to opposite conclusions of additional diodes. If diodes are serviceable, the tester will show resistance of 550-600 Ohm.	16. Connect щупы a tester to additional diodes, having changed polarity. If diodes are serviceable, the tester will show infinitely big resistance.

17. Replace the vypryamitelny block if at check you find at least one faulty diode.

18. Check a stator winding on break, serially measuring by a tester resistance between all conclusions of a winding. If the measured resistance aspires to infinity, replace a stator.	19. Connect щупы a tester to the case of a stator and serially to each conclusion of a winding. The measured resistance should be very big (to aspire to infinity). Otherwise replace a stator.

20. Otpayayte a conclusion of a regulator of tension from a conclusion of the vypryamitelny block.	21. A face head «on 7» turn out two bolts of fastening of a regulator of tension to a back cover of the generator...

22.... also remove a tension regulator.

Note So the tension regulator looks. Pay attention to its marking that at replacement of a regulator to get just the same.

23. Otpayayte three conclusions of a winding of a stator from conclusions of the vypryamitelny block.	24. A key «on 15» turn out a contact hairpin of a conclusion generator "plus".

25. Examine a contact hairpin. Replace it if will find overheat or podgoraniye traces.	26. A face head «on 7» turn out two bolts of fastening of the vypryamitelny block to a back cover of the generator...

27.... also remove the vypryamitelny block.

Note So the removed vypryamitelny block looks from a protective casing... ... and so – from a stator.

28. Remove an insulator of conclusions of a winding of a stator.	29. Examine the removed insulator. The damaged insulator replace.

30. A face head of TORX E8 turn out four coupling bolts.	31. Having hooked a screw-driver, remove a forward cover of the generator.

32. Examine a forward cover of the generator. The plastic plug of the forward bearing of a rotor of the generator should be densely established in an opening of a cover and on it. At the correct landing of the bearing in the plug on it there should not be traces of a proskalzyvaniye of an external ring of the bearing. If cover cracks, especially in places of fastening of the generator are found, it is necessary to replace a cover new.

33. Clamp in a vice a generator pulley through an old belt...

34.... also unscrew a cap key or a face head «on 24» a nut of fastening of a pulley.	35. Take out a rotor shaft from an opening of a pulley of the generator.

Note The pulley of the generator is fixed from a provorachivaniye on a rotor shaft only at the expense of forces of a friction after an inhaling of a nut of its fastening by the demanded moment. Shponka in connection is absent.

36. Take out a generator rotor from a forward cover.	37. Examine contact rings. If on them there are teases, risks, scratches, wear tracks from brushes and other defects, прошлифуйте rings. If damage of rings does not manage to be deduced a skin, it is possible to pierce rings on the lathe, having removed the minimum layer of metal, and then прошлифовать them.

38. Check ease of rotation of the bearing from contact rings. If at rotation of the bearing the rift or jamming of bodies of a kacheniye is felt люфт between rings, protective rings are damaged or there are traces of a podtekaniye of greasing, it is necessary to replace the bearing. For this purpose...

39.... press the bearing from a landing neck of a shaft of a rotor...	40.... also remove the bearing from a shaft.

41. Napressuyte the new bearing on a rotor shaft against the stop in a shaft fillet, putting effort to an internal ring of the bearing through an opravka of suitable diameter.	42. Mark a relative positioning of a stator and a forward cover.

43. Accurately hook a stator a screw-driver...	44.... also separate a stator and a forward cover of the generator.

45. Examine a back cover of the generator. If at rotation of the bearing the rift or jamming of bodies of a kacheniye is felt люфт between rings, protective rings are damaged or there are traces of a podtekaniye of greasing, replace the bearing. If cracks in a cover, especially in places of fastening of the generator are found, it is necessary to replace a cover new.	46. For replacement of the back bearing of a shaft of a rotor выпрессуйте it from a cover.

47. Press the new bearing in a cover an opravka of suitable diameter, putting effort to an external ring.

48. Collect the generator as it should be, the return to dismantling, сориентировав covers of the generator and a stator on earlier made labels.