8.2.2. Service of the generator
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Implementation of the procedures described below will require the voltmeter and the ampermeter with a range of measurement of 80-0-80 A. |
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- You watch polarity of connection of the battery (see size tables and adjustments at the end of the Management).
- Do not short-circuit and do not ground the plugs, general with a charging contour.
- Before connection of the charger disconnect the battery.
- When using the auxiliary battery connect it in parallel, i.e. plus to plus, minus to minus that the general output tension remained equal 12 Century.
- Do not disconnect the battery or plugs of a charging contour at the working engine at all.
- Regularly check a state and effort of a tension of a driving belt (it).
- You watch purity of plugs of the battery and reliability of fastening of all contact connections.
- When performing electrowelding works on the car without fail switch-off the battery and the generator.
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Check on the car
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If the control lamp of a charge remains included after start of the engine and installation of its turns on value 1 000 in a minute or if there are bases to suspect violation of level of a charge of the battery in this or that party, execute a series of the listed below checks. |
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- Kill the engine.
- Check correctness of adjustment of a tension of a driving belt (it).
- Check a condition of a fusible insert.
- Smooth out battery plugs. Tighten all contact connections, checking an electrical wiring for short circuit.
- Check battery charge level. If it is small, recharge the battery, or replace it.
- Start the engine and warm up it up to the normal working temperature.
- Kill the engine and disconnect a negative wire from the battery.
- Give a nut of fastening of the output plug (VAT) of the generator (on an accompanying illustration the generator of the engine of 4.2 l is shown), remove a washer and disconnect an output wire of the generator.
- Connect one of ampermeter 80-0-80 wires to the output plug of the generator, the second - to an output wire.
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Do not use for connection of wires of the ampermeter clips like "crocodile". It is necessary to apply bolted clips or special collars - the casual detachment of wires during check can lead to failure of diode assembly of the generator. |
- Connect a negative wire to the battery, between plugs of the battery turn on the voltmeter.
- Connect a tachometer.
- Turn on driving beam of head headlights. Leave headlights included for the period of about five minutes for decrease in level of a charge of the battery and creation of load of a contour.
- Start the engine and gradually lift its turns to value about 2 500 in a minute. The indication of the ampermeter has to make about 75% of nominal rate of this generator (see size tables and adjustments at the end of the Management).
- Switch off all lighting fixtures and dump engine turns to 2 000 in a minute, trying to obtain falling of instrument reading is lower than level 10 A. Tension at the same time has to get to an interval from 14.1 to 14.7 Century.
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If the generator does not provide the required output characteristics, it has to be removed for performance of capital repairs or replacement. If the measured tension goes beyond the stipulated limits, it is necessary to replace tension regulator. |
Removal and installation
Carburetor models of 4.2 l and 3.0 l
Removal
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- Disconnect a negative wire from the battery.
- Give a nut of the output plug (VAT) of the generator, remove a washer and disconnect an output wire.
- Release a clip and disunite the electric socket in a back part of the generator.
- Give a bolt of the plug E and remove from the generator the noise suppressor with a wire.
- Give a lock bolt of adjustment of situation, remove bolted assembly about a driving belt (belts).
- On models of 3.0 l, supporting the generator, give fixing a bolt with a nut and remove the remote plug.
- On models of 4.2 l, supporting the generator, give fixing bolts.
- Remove the generator from the car.
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Installation
Installation is made upside-down.
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- Do not draw a driving belt (belts) with excessive effort.
- Track for reliability of fastening of contact plugs and sockets of the generator.
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Models of 4.2 l of EFI (since 1992 the issue)
Removal
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- Disconnect a negative wire from the battery.
- Remove the fuel filter from an arm and take him aside from the generator.
- Give fixing bolts and remove an arm of the fuel filter from the generator.
- Give a lock bolt of adjustment of position of the generator and a bolt of fastening of an adjusting bracket. Remove a bracket from the generator.
- Disconnect an electrical wiring from the generator.
- Supporting the generator, give its axial bolts. Remove the generator from the car.
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Installation
Installation is made upside-down.
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- Establish driving belts and adjust effort of their tension.
- Track reliability of fastening of electric sockets.
- Do not forget to connect a grounding wire to an arm of the fuel filter.
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Dismantling
Carburetor models of 4.2 l and 3.0 l
Components of the generator of the engine of 4.2 l
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- Remove the generator from the car.
- Give fixing screws and remove (if that is established) a plastic cover from the back party of the generator.
- Draw to risk on a cover from the drive, to the stator and a cover from the sliding rings, having marked with that the provision of components from each other.
- Take through bolts of fastening of a cover from the drive to a cover from the sliding rings.
- Having carefully hooked suitable levers, remove assembly of a cover from the sliding rings with the stator from assembly of a cover from the drive with a rotor. In order to avoid damage of the stator, you do not enter levers too deeply.
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If assembly of a cover from the sliding rings with the stator does not give in, it makes sense to warm up it within 3 ÷ 4 minutes around a ledge under installation of the bearing powerful (200 W) a soldering iron. |
- Clamp assembly of a cover from the drive with a rotor in a vice soft sponges and give a nut of fastening of a driving pulley to a rotor.
- Remove a pulley, a krylchatka of the fan and the remote plug of a shaft of a rotor.
- By means of the hammer with soft brisk beat out assembly of a rotor from a cover and remove the remote plug from a rotor shaft.
- In case of need give screws of fastening of a plate of the holder of the bearing to a cover from the drive and carefully take the bearing from a cover.
- In case of need remove from a rotor shaft the bearing from the sliding rings for what use a suitable stripper.
- Give nuts and remove from a cover from the sliding rings a washer and the insulator.
- Uncover assembly of the stator.
- In case of need unsolder from the stator diode assembly the regulator.
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Try not to overheat contacts in order to avoid damage of diode assembly and/or the regulator. Clamp a wire flat-nose pliers as it is possible closer to the place of soldering - flat-nose pliers will execute a heat sink role.
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Models of 4.2 l of EFI (since 1992 the issue)
Components of the generator of models of 4.2 l of EFI
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- Remove the generator from the car.
- Draw to risk on a cover from the drive, to the stator and a cover from the sliding rings, having marked with that the provision of components from each other.
- Take through bolts of fastening of a cover from the drive to a cover from the sliding rings.
- Having carefully hooked suitable levers, remove assembly of a cover from the sliding rings from the drive with a rotor. In order to avoid damage of the stator, you do not enter levers too deeply.
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If assembly of a cover from the sliding rings with the stator does not give in, it makes sense to warm up it within 3 ÷ 4 minutes around a ledge under installation of the bearing powerful (200 W) a soldering iron. |
- Clamp assembly of a cover from the drive with a rotor in a vice soft sponges.
- Give a nut of fastening of a driving pulley to a rotor and remove a pulley.
- By means of the hammer with soft brisk beat out assembly of a rotor from a cover and remove the remote plug from a rotor shaft.
- In case of need give screws of fastening of a plate of the holder of the bearing to a cover from the drive and carefully take the bearing from a cover.
- In case of need remove from a rotor shaft the bearing from the sliding rings for what use a suitable stripper.
- Give nuts and remove from a cover from the sliding rings the insulator. Uncover assembly of the stator.
- In case of need give fixing screws and remove the rectifier, the regulator and brush assembly from the stator.
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Cleaning of components
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- In order to avoid damage of windings do not lower generator components in solvent.
- Face covers can be washed out in kerosene or other cleaning liquid after removal from the block. Then they should be dried carefully.
- For removal of dust from windings of the stator and a rotor it is possible to use compressed air.
- The burned or scratched sliding contact rings can be polished by means of a thin emery paper.
- Wipe brushes and brush holders with the rags moistened in gasoline. Examine brush holders, remove from them agnails.
- Check bearings for existence of signs of wear, estimate freedom of their rotation and a condition of lubricant. In case of need replace.
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Check of a state and serviceability of functioning of components
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All components which are subject to electric checks should be installed on dielectric supports. |
Assembly of a rotor with excitement windings
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- Check of short circuit of windings on weight is made by means of an ohmmeter. Connect one of measuring probes of the device to one of excitement windings / the sliding rings, and the second - to one of polar tips of a rotor (see an accompanying illustration).
- If conductivity takes place, and the visible reasons of short circuit do not manage to be revealed and eliminated, replace assembly of a rotor.
- For check of resistance of windings of a rotor connect measuring probes of an ohmmeter to the sliding rings (see an accompanying illustration). If conductivity is absent, replace a rotor.
- Check of the stator is made by means of a lamp of a sampler and an ohmmeter.
- Wires of the stator need to be disconnected from assembly of the rectifier.
- Connect one of measuring probes of an ohmmeter to one of stator wires, the second probe - to the second wire. Consider instrument reading.
- Repeat measurement for the remained wires, we will check thereby all phases.
- If between results of measurements there is a difference assembly of the stator it is necessary to replace.
- Connect a wire crossing point between the negative plug of the charged 12-free battery and an obmotochny frame of the stator. Serially connect one of lamp sampler wires to all wires of the stator.
- Inclusion of a paw of a sampler (soft luminescence) should be regarded as a sign of existence of short circuit. Assembly of the stator at the same time has to be replaced.
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Diode assembly
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Diode assembly can be checked by means of an ohmmeter after its removal from the stator. |
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- Connect measuring probes of an ohmmeter between the case and one of contacts of diode assembly. Change an order of connection of probes for the return and make sure that conductivity takes place only in one direction.
- Repeat check for all other contacts of assembly. If the condition of check is not satisfied (conductivity on any of contacts takes place in both directions, or in general is absent), replace diode assembly.
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Brushes and brush springs
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- Check springs of brushes for existence of signs of an overheat and deformation. Check freedom of sliding of brushes in brush holders.
- Measure length of brushes, compare result of measurements to requirements of size tables and adjustments, in case of need replace brushes.
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Assembly
Assembly is made as it should be, the return to a dismantle order.
Carburetor models of 4.2 l and 3.0 l
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- Install the new bearing in a cover from the drive, fix by its plate the holder, tighten fixing screws.
- Install the new bearing on a rotor from the sliding rings, - it is necessary to press an internal holder. Track that the flute under installation of a lock ring did not get under the sliding rings.
- Establish a lock ring with turned to the sliding rings of the party of the bearing. Track that the acting part of a ring appeared the flute located in the deepest part.
- By means of a soldering iron and couple of dinnogubets (as the heat sink) solder contacts of diode assembly and the regulator to assembly of the stator.
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In order to avoid failure of diodes and/or the regulator try not to overheat contacts excessively. Before the soldering make sure of correctness of placement of wires of diode assembly. |
- Establish assembly of the stator, rectifier and regulator in a cover from the sliding rings and screw fixing nuts.
- Install a cover, a washer and nuts on the generator VAT plug.
- Record brushes in the speaker situation by means of the wire piece (the straightened paper clip) passed throughout a special opening in a cover from the sliding rings.
- Clamp a rotor in a vice with soft sponges and put on its shaft a cover from the sliding rings assembled with the bearing.
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In case of need warm up a cover within 3 ÷ 4 minutes around installation of the bearing powerful (200 W) a soldering iron. |
- Put on a rotor shaft a cover from the drive with the bearing. Track correctness of installation of the remote plug.
- Achieve combination of tags of mutual provision of knots of the generator, then screw and strongly tighten through bolts.
- Put on the remote plug, a krylchatka of the fan, a pulley and a spring washer a rotor shaft, then screw a nut and tighten it with the required effort.
- Remove a wire (paper clip) used for fixing of brushes in the speaker situation and manually check freedom of rotation of a rotor.
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Models of 4.2 l of EFI (since 1992 the issue)
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- Install the new bearing in a cover from the drive, fix by its plate the holder, tighten fixing screws.
- Install the new bearing on a rotor from the sliding rings (it is necessary to napressovyvat an internal holder).
- Establish a rotor shaft in a cover from the drive (track correctness of installation of the remote plug).
- Establish a pulley on a rotor shaft and tighten a nut of its fastening with effort of 49 ÷ 64 Nanometers.
- Clamp assembly of a cover from the drive with a rotor in a vice with soft sponges.
- Record brushes in the speaker situation by means of the piece of a wire passed throughout a special opening in a cover from the sliding rings.
- Put on assembly of a rotor a cover from the drive with the bearing. Achieve combination of tags of mutual provision of knots of the generator.
- Screw through bolts and tighten them with effort of 3 ÷ 4 Nanometers, take a wire (paper clip) used for fixing of brushes in the speaker situation then manually check freedom of rotation of a rotor.
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