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Generator Service
 | To perform the procedures described below require a voltmeter and an ammeter with a measuring range 80-0-80 A. |
| - Watch out for the polarity of the battery connection (see. Table sizes and adjustments in the end of this manual).
- Do not short or ground the common terminal to the charging circuit.
- Before connecting the charger disconnect the battery.
- When using an auxiliary battery connect it in parallel, ie, positive to positive, negative to negative, so that the total output voltage of 12 V. remained
- In no case do not disconnect the battery or charging circuit terminals with the engine running.
- Regularly check the condition and the tension of the drive belt (s).
- Keep the battery terminals and reliability of fastening of all contact connections.
- When performing electric welding work on the vehicle without fail disconnect the battery and the generator.
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Checking on the vehicle | If the warning light stays on charge after starting the engine and set its value at RPM 1000 per minute, or if there is reason to suspect a violation of the battery level in one direction or another, perform a series of checks listed below. |
| - Stop the engine.
- Check the drive belt tension adjustment (s).
- Check the condition of fuse.
- Strip the battery terminals. Tighten all contact connections, checking the wiring for a short circuit.
- Check the battery level. If it is low, recharge the battery or replace it.
- Start the engine and warm it up to normal operating temperature.
- Stop the engine and disconnect the wire from the battery.
- Give a nut fastening the output terminal (BAT), generator (on an accompanying illustration shows a generator engine 4.2 liters), remove a washer and disconnect the output of the generator.
- Connect one of the wires in the ammeter 80-0-80 to the output terminal of the generator, the second - the output wire.
| Do not use wires to connect an ammeter clamp type "crocodile". It is used bolt clamps or special collars - accidental disconnection of the wires during the test may result in failure of the diode assembly of the generator. |
- Connect the negative cable to the battery between the battery terminals include a voltmeter.
- Connect the tachometer.
- Turn on the main beam headlights. Leave the lights on for about five minutes of time to reduce battery load and creating a loop.
- Start the engine and slowly lift it turns to a value of about 2500 per minute. The ammeter reading should be about 75% of the nominal value of the generator (see. Table sizes and adjustments in the end of this manual).
- Turn off all lights and reset the engine speed to 2000 per minute, achieving readings fall below 10 A. The voltage thus must fall within the interval from 14.1 to 14.7 V.
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| If the generator does not provide desired output characteristics, it must be removed to perform the overhaul or replacement. If the measured voltage is outside the specified limits, replace the voltage regulator. |
Refitting Carburettor models 4.2 l and 3.0 l Withdrawal | - Disconnect the negative wire from the battery.
- Give a nut output terminal (BAT) generator, remove a washer and disconnect the output wire.
- Release the clamp and disunite an electric socket at the back of the generator.
- Give screw terminals E and remove the wire from the generator squelch.
- Give adjust the position of the locking bolt, remove the bolt-assembly of the drive belt (s).
- On models 3.0 l, maintaining the generator, give the fastening bolt with a nut and remove the spacer sleeve.
- On models 4.2 l, maintaining the generator, give fixing bolts.
- Remove the generator from the car.
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Setting Installation is in the reverse order. | - Do not overtighten with excessive force drive belt (s).
- Track reliability of fastening of contact plugs and sockets of the generator.
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Models of 4.2 l EFI (1992 vol.) Withdrawal | - Disconnect the negative wire from the battery.
- Remove the fuel filter bracket and move it away from the generator.
- Give fixing bolts and remove the generator from the fuel filter bracket.
- Give the locking bolt adjustment of the generator and an adjusting bolt clamps. Remove the bracket from the generator.
- Disconnect the electrical wiring from the generator.
- Supporting the generator, give it to the axle bolt. Remove the generator from the car.
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Setting Installation is in the reverse order. | - Install belts and adjust the tension of the effort.
- Track reliability of fixing the electrical connectors.
- Do not forget to connect to an arm of the fuel filter ground wire. .
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Dismantling Carburettor models 4.2 l and 3.0 l The components of the generator engine 4.2 l
| - Remove the generator from the car.
- Give fixing screws and remove (if installed) the plastic cover on the back side of the generator.
- Draw a risk on the cover of the drive side, the stator and the cover by sliding rings, thereby marking the position of the components relative to each other.
- Remove the cover bolts through the drive side to the cover by sliding rings.
- Cautiously having hooked suitable levers, remove the lid assembly from sliding rings to the stator assembly with the cover from the drive to the rotor. To prevent damage to the stator arms do not enter too deeply.
| If the assembly cover by sliding rings to the stator can not be, it makes sense to warm up for 3 ÷ 4 minutes in the area of the projection for the installation of bearing powerful (200 W) soldering iron. |
- Clamp assembly cover from the drive to the rotor in a vice soft sponges and hand nut drive pulley to the rotor.
- Remove the pulley and the fan wheel spacer sleeve of the rotor shaft.
- Using a hammer with soft brisk beat out a rotor assembly of the cover and remove from the rotor shaft the remote plug.
- If necessary, give the mounting screws of the bearing plate to the cover from the drive and gently pull the bearing from the cover.
- If necessary, remove the rotor shaft bearing from sliding rings, which use a suitable puller.
- Give nuts and remove the cover from sliding rings washer and insulator.
- Remove the cover from the stator assembly.
- If necessary, from the stator Unsolder regulator diode assembly.
| Be careful not to overheat contacts to avoid damaging the diode assembly and / or regulator. Hold the wire with pliers as close as possible to the place of soldering - pliers fulfill the role of a heat sink. |
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Models of 4.2 l EFI (1992 vol.) The components of the generator model 4.2 liter EFI
| - Remove the generator from the car.
- Draw a risk on the cover of the drive side, the stator and the cover by sliding rings, thereby marking the position of the components relative to each other.
- Remove the cover bolts through the drive side to the cover by sliding rings.
- Cautiously having hooked suitable levers, remove the lid assembly from sliding rings from the drive to the rotor. To prevent damage to the stator arms do not enter too deeply.
| If the assembly cover by sliding rings to the stator can not be, it makes sense to warm up for 3 ÷ 4 minutes in the area of the projection for the installation of bearing powerful (200 W) soldering iron. |
- Clamp assembly cover from the drive to the rotor in a vice with soft sponges.
- Give the nut to the rotor drive pulley and remove the pulley.
- Using a hammer with soft brisk beat out a rotor assembly of the cover and remove from the rotor shaft the remote plug.
- If necessary, give the mounting screws of the bearing plate to the cover from the drive and gently pull the bearing from the cover.
- If necessary, remove the rotor shaft bearing from sliding rings, which use a suitable puller.
- Give nuts and remove the cover from sliding rings insulator. Remove the cover from the stator assembly.
- If necessary, give fixing screws and remove the stator from the rectifier, regulator and brush assembly.
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Shoe components | - To avoid damage to the windings do not lower components of the generator in the solvent.
- End caps can be washed in kerosene or other cleaning fluid after removal from the unit. Then, they should be thoroughly dried.
- To remove dust from the stator and rotor windings can use compressed air.
- The scorched or scratched sliding contact rings can be polished using fine sandpaper.
- Clean brushes and brush holders soaked in gasoline with a cloth. Inspect brush holders, remove them with a hangnail.
- Check the bearings for signs of wear, enjoy the freedom of their rotation and the condition of the lubricant. Replace if necessary.
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Check the condition and serviceability of functioning of components | All checks to be electrical components should be installed on insulating supports. |
Assembling the rotor excitation windings | - Check short-circuit the windings to ground is made by means of an ohmmeter. Connect one of the test leads of the device to one of the field coils / sliding rings, and the second - to one of the pole pieces of the rotor (see. Accompanying illustration).
- If conductivity takes place, and see no reason to identify a short circuit and persists, replace the rotor assembly.
- To check the rotor winding resistance connect ohmmeter probes to the slip ring (see. Accompanying illustration). If conductivity is absent, replace the rotor.
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- Checking the stator is carried out using lamps and probe ohmmeter.
- The wires must be disconnected from the stator assembly of the rectifier.
- Connect one ohmmeter test leads to one of the wires of the stator, the second probe - the second wire. Consider reading.
- Repeat the test for the remaining wires, thereby check all phases.
- If between the measurements there is a difference stator assembly must be replaced.
- Connect the jumper wire between the negative terminal of the charged battery 12 freestyle and the winding of the stator frame. Alternately connect one wire of the lamp-wire probe to all of the stator.
- Enabling probe paw (dim lighting) should be considered as an indication of the presence of a short circuit. Wherein the stator assembly has to be replaced.
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Diode Arrays | The diode assembly can be checked using an ohmmeter after removing it from the stator. |
| - Connect the probes of an ohmmeter between the housing and one of the terminals of the diode assembly. Change how to connect the probe to the back and make sure that the conductivity takes place only in one direction.
- Repeat the test for all contacts assembly. If the test condition is not satisfied (the conductivity in any of the contacts takes place in both directions, or absent), replace the diode assembly.
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Brushes and brush spring | - Check the brush springs for signs of overheating and distortion. Check freedom of sliding brushes in the brush holders.
- Measure the length of the brush, compare the measurement result with the requirements of table sizes and adjustments, if necessary, replace the brush.
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Assembly Installation is the reverse order of removal. Carburettor models 4.2 l and 3.0 l | - Install a new bearing cover on the drive side, fix its plate holder and tighten the screws.
- Install the new bearing on the rotor side sliding rings - must be pressed on the inner ring. Make sure that the groove for the installation of a lock ring has not got a sliding ring.
- Install the snap ring facing the slip ring side of the bearing. Make sure that the protruding part of the ring proved to lie in the deepest part of the groove.
- Using a soldering iron and a pair dinnogubtsev (as a heat sink) solder contacts diode assembly and control to the stator assembly.
| To avoid failure of the diodes and / or control over, try not to overheat contacts. Before starting soldering make sure the correct placement of the wires of the diode assembly. |
- Install the stator assembly, rectifier and regulator cover by sliding rings and screw the mounting nut.
- Replace the cover, the washer and nut on the BAT terminal of the generator.
- Secure the brush in the extended position by a piece of wire (a straightened paper clip) inserted in the hole in the lid by sliding rings.
- Clamp the rotor in a vice with soft sponges and put on its shaft cover by sliding rings and bearing assembly.
| If necessary, warm up the cover for 3 ÷ 4 minutes near the bearing powerful (200 W) soldering. |
- Put the lid on the rotor shaft on the drive side bearing. Track correctness of installation of the remote bush.
- Achieve combination of labels relative position of nodes of the generator, then screw and tighten the through bolts.
- Put on the rotor shaft the remote plug, the fan wheel, pulley and spring washer, then screw the nut and tighten it with demanded effort.
- Remove the wire (paper clip) used to secure the brushes in the extended position and manually check up freedom of rotation of the rotor.
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Models of 4.2 l EFI (1992 vol.) | - Install a new bearing cover on the drive side, fix its plate holder and tighten the screws.
- Install the new bearing on the rotor side sliding rings (to be pressed onto the inner ring).
- Install the rotor shaft in the cover on the drive side (track correctness of installation of remote bush).
- Install the pulley on the rotor shaft and tighten the nut of its fastening with effort 49 ÷ 64 Nm.
- Clamp assembly cover from the drive to the rotor in a vice with soft sponges.
- Lock brush in the extended position by means of a piece of wire, is threaded into the hole in the cover by sliding rings.
- Put on the lid of the rotor assembly from the drive end bearing. Achieve combination of labels relative position of nodes generator.
- Screw through-bolts and tighten them with a force of 3 ÷ 4 Nm, take wire (paper clip) used to secure the brushes in the extended position, then manually check up freedom of rotation of the rotor.
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