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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Hyundai Getz (2002 release)

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Generator



Hyundai vehicles are equipped with alternators. Depending on the model and modifications may be set different power generators. Power is listed on the nameplate of the generator.
Generator with built-in voltage regulator enters the system of charging the battery, which itself includes the battery and test lamp wiring.
The generator is equipped with six built-in diode (three 'positive' and three 'negative'), converts the alternating current to direct current. Therefore, through the withdrawal of the "B" issued by a direct current generator.
Additionally, developed by the generator voltage is regulated by the charging control of the battery voltage. The main components are the generator rotor, stator, rectifier unit, brushes, bearings and belt drive pulley. The brush holder integrated electronic voltage regulator.

A WARNING
When installing optional equipment, check whether there is enough power generator of the former; If necessary, install a more powerful generator and the battery.

The generator is driven by the crankshaft via the V-belt. The rotor of the generator excitation winding rotates within the fixed stator winding with a frequency of twice the speed of the engine crankshaft.
As carbon brushes and slip rings of the generator through the field winding excitation current flows. Creates a magnetic field.
The position of the magnetic field relative to the stator winding changes continuously in accordance with the rotational direction of the rotor. Due to this in the stator winding produces an alternating electrical current.
Because the battery can be charged only with direct current, alternating current is converted to DC rectifier diode board generator. The voltage regulator changes the charging current on and off the field current, depending on the state of charge of the battery. At the same time the voltage regulator maintains the battery voltage is constant at 14, regardless of the engine speed of the engine.

Safety in the repair and maintenance of generators
Before performing any work on the system of charging the battery, review the following safety precautions.
When working with elements of the electrical system in the engine compartment, always unplug the cable of "weight" from the negative terminal of the battery.

A WARNING
When you disconnect the wire from the negative terminal of the battery erases the data from the memory of the electronic control unit of the injection and the security code radio. If the radio is coded, before disconnecting, make sure that you know the security code. Without him after power receiver is not turned on.

Do not mix the cables and generator voltage regulator. Before disconnecting, mark them with tape.
Do not disconnect the battery or voltage regulator with the engine running.
Do not remove the generator when the connected battery.
When carrying out electrical welding work, always unplug the battery.

Checking the technical condition of the generator
Check the voltage drop at the output of the generator

Driving test voltage drop across the output of the generator
Fig. 7.4. Driving test voltage drop across the output of the generator 1 - the generator; 2 - fuse; 3 - voltmeter; 4 - battery


Driving test voltage drop across the output of the generator is shown in Fig. 7.4.
The test is performed to determine the serviceability of the wire between terminal "B" of the generator and the terminal "+" of the battery voltage drop on the wire.
Set the key in the ignition switch to ?«OFF?» (off).

NOTE
To determine the reliability of the wire connections at check not touch both terminals and connections.

Connect the positive lead ("+") of the digital voltmeter to the "B" of the generator and negative cable ("-") of the voltmeter to the terminal "+" of the battery.
Indications voltmeter read when the engine is running, the head lights, passenger compartment blower and other electrical consumers.
The voltage on the voltmeter should be 14 V.
If the measured voltage is different to 0.3 V, this indicates a fault in the wiring. Check the wires that connect the output "B" of the generator through the fuse-link to the terminal "+" of the battery.
Check the wiring for loose connections or change the colors of the wires from overheating. Correct the problem and recheck.
After checking, allow the engine to idle, then turn off the lights, the fan compartment and other energy consumers, switch off the ignition.

Checking the current output of the generator
Verification is carried out to determine whether the current output of the generator nominal value.

Driving test current output of the generator
Fig. 7.5. Driving test current output of the generator 1 - the storage battery; 2, 3 - fuses; 4 - the ignition switch; 5 - a control lamp Charging the battery; 6 - voltmeter; 7 - ammeter


Driving test current output of the generator is shown in Fig. 7.5.
Before testing, check the following, and repair if necessary.
Check that is installed on the vehicle battery.

NOTE
When checking the current output of the generator, the battery should be partially discharged. When fully charged battery test result will be inaccurate due to insufficient load generator.

Check the tension of the alternator drive belt.
Set the ignition key to ?«OFF?» (off).
Disconnect a wire from "the minus" plug of the storage battery.
Disconnect the output "B" of the generator.
Connect the DC ammeter (with a limit of measurement 0-100 A) sequentially to the conclusion "B" and disconnecting the alternator output wire. The wire from the output "-" connect the ammeter to the disconnected output wire.

NOTE
Because of the large current tighten both compounds. Do not use the terminals of the "Crocodile".

Connect a voltmeter (a limit of measurements 0-20) concluded "B" and "weight", "plus" wire ("+") voltmeter - concluded "B" of the generator and "minus" line ("-") - securely to the "masses."
Attach the tachometer to control the speed of the crankshaft of the engine, connect a wire from the negative terminal of the battery.
Leave the hood open.
Make sure that the voltmeter shows battery voltage. If the voltmeter shows 0, the possible causes are an open wire between terminal "B" terminal of the generator and "-" battery, blown fuse or bad connection with "weight".
Start up the engine and turn on the lights.
Turn on the main beam headlights and the heater fan at a very high speed, dramatically increase the engine speed up to 2500 min -1 and lock on the ammeter maximum current impact of the generator.
The ammeter reading should be less than the limit value (see. Below). If it is lower than in the proper output of the generator, remove the generator from the car and check it out.
The maximum allowable current impact of the generator, A, not less than:
A generator 70 ..... 49.0
A generator 90 ..... 63.0

NOTE
Nominal current output specified on the label attached to the casing of the generator, so the current value of the current output can differ from the nominal. In this case, turn on lights, to discharge the battery.

After the test current output, lower the engine speed to idle and turn the ignition off.
Disconnect the negative battery terminal.
Disconnect the ammeter, voltmeter and check the tachometer.
Connect the output wire to the "B" of the generator.
Attach the wire to the negative terminal of the battery.

NOTE
When the engine starts charging current decreases rapidly. For true maximum current above operations should be carried out by spending as little time.

Checking the regulated voltage
The purpose of this test is to verify the performance of the electronic voltage regulator.

Driving test the built-in voltage regulator
Fig. 7.6. Driving test the built-in voltage regulator: 1, 3 - fuses; 2 - the ignition switch


Driving test the built-in voltage regulator is shown in Fig. 7.6.
Pre-check the following and repair if necessary:
- Check the set on the car battery;
- Check the tension of the alternator drive belt.
Set the ignition key to ?«OFF?» (off).
Disconnect a wire from "the minus" plug of the storage battery.
Connect a digital voltmeter to
found ?«S (L)?» generator and to "weight" ("plus" wire ("+") voltmeter - concluded ?«S (L)?» generator and "minus" voltmeter ("-") - a "negative "terminal (" - ") battery).
Disconnect the alternator output wire from the terminal "B".
Connect the DC ammeter (with a limit of measurement 0-100 A) sequentially to the conclusion "B" and disconnecting the alternator output wire. "Minus" line ("-") connect the ammeter to the disconnected output wire.
Attach the tachometer to control engine speed and connect the wire to the "minus" pole of the battery.
Turn on the ignition and check that the voltmeter shows battery voltage. If the voltmeter shows 0, then the cause is an open circuit between terminal ?«S (L)?» generator and "plus" terminal ("+") battery or blown fuse.
Start up the engine, turn off the lights and all electrical consumers.
Increase the engine speed of about 2500 min -1 and fix the voltmeter reading when the current impact of the generator to 10 amps or less.
If the voltmeter reads values laid down in Table. 7.5, the voltage regulator is operational.

Table 7.5
The limits of the regulated voltage
Ambient
air, ?° C
The limits of the regulated voltage,
A generator 75
A generator 90
-20
14,2-15,4
14,3-15,2
20
13,9-14,9
14,1-14,7
60
13,4-14,6
13,5-14,4
80
13,1-14,5
13,3-14,3

If the voltmeter readings differ from the norm, the voltage regulator is defective.
After testing, reduce the engine speed to idle and turn the ignition off.
Disconnect a wire from "the minus" plug of the storage battery.
Disconnect the voltmeter, ammeter and check the tachometer.
Connect the output wire to the "B" of the generator.
Attach the wire to "the minus" plug of the storage battery.

Removing and installing the generator

Alternator drive belt tensioner and the drive belt
Fig. 7.7. Alternator drive belt tensioner and the drive belt: 1 - tensioning strap; 2 - a bolt; 3 - an arm of fastening of the generator; 4 - the water pump pulley; 5 - the crankshaft pulley; 6 - generator; 7 - a bolt of fastening of the generator; 8 - The front cover of the cylinder; 9 - a nut bolts generator


Alternator drive belt tensioner and the drive belt shown in Fig. 7.7.
Disconnect a wire from "the minus" plug of the storage battery.

Pin generator
Fig. 7.8. Pin generator


Disconnect the generator (Fig. 7.8) and disconnect the wire from the output "B +".

Bolt tensioning straps alternator drive belt
Fig. 7.9. Bolt tensioning straps alternator drive belt


Loosen the bolt tensioning straps alternator drive belt and unscrew a bolt of fastening of the generator (Fig. 7.9).
Remove the drive belt by moving the generator to the crankshaft pulley and the water pump.

Lower suspension generator in the front cover of the cylinder
Fig. 7.10. Lower suspension generator in the front cover of the cylinder


Remove the generator (Fig. 7.10).
Installation of the generator is carried out in reverse order.
Install the generator in place and insert the bolt (bolt nut does not turn).

Installation gap generator lower support
Fig. 7.11. Installation gap generator lower support


Move the generator away from the engine and determine the number of spacers (washers thickness 0.198 mm), which must be installed between the front desk and the generator housing front cover of the cylinder (A gap on Fig. 7.11). Number of goals should be such that they do not fall out when released).
Install the washers (gap A), tighten the nut bolts and run the rest of the installation operation.

Disassembly and assembly of the generator

Generator
Fig. 7.12. Generator: 1 - a nut; 2 - a pulley; 3 - remote bush; 4 - a cover from outside a drive; 5 - front bearing of the rotor; 6 - insert the front bearing of the rotor; 7 - the bolts of the front rotor bearing plate; 8 - rotor; 9 - rear rotor bearing; 10 - a cover of the bearing; 11 - stator; 12 - coupling bolt; 13 - a sealing ring; 14 - rectifier unit; 15 - pin; 16 - the brush holder; 17 - Brush holder fixing screws; 18 - mounting sleeve slip rings; 19 - a cover from outside contact rings


The generator is shown in Fig. 7.12.
Dismantling
Use a screwdriver to remove the cover from the generator slip rings.

Bolts brush holder
Fig. 7.13. Bolts brush holder


Remove the brush holder by unscrewing the screws (Fig. 7.13).
Remove the mounting sleeve slip rings.
Loosen the nut of the pulley and remove the pulley and the spacer sleeve.

Tightening bolts of the generator
Fig. 7.14. Tightening bolts of the generator


Remove the four coupling bolts (Fig. 7.14).
Undock the cover on the drive side, rotor and stator.
The assembly is carried out in reverse order.
Technical condition
Rotor. Check the integrity of the rotor winding. Check the continuity between the slip rings. Extremely low resistance connection between the rings indicates the presence of a short circuit. In the absence of a chain between the rings or short circuit between them, replace the rotor.
Resistance should be around 3.1 Ohm.
Check on the field winding insulation to the "masses." Check for continuity between slip ring and rotor core. In the presence of the chain, replace the rotor.
Stator. Check the stator winding for broken. Ensure that there is continuity between the winding wires. In the absence of a chain, replace the stator.
Check winding insulation to the "masses." Check for continuity between coil and core. In the presence of the chain, replace the stator.
Replacement brush

Brush holder (brush wear limit line is specified by an arrow)
Fig. 7.15. Brush holder (brush wear limit line is specified by an arrow)


Replace brushes when worn to the wear limit line (Fig. 7.15).
Unsolder wire brush, remove the old brush and spring.
Insert the brush spring and a new brush into the brush holder.
Insert the brush so that the distance between the line of limit of wear of the brush and the brush holder edge was 2-3 mm.
Solder the wire brush to brush holder.




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