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Dismantling, check and assemblage of the generator
| Fig. 7.19. The components of the generator: 1 - a pulley; 2 - O-ring; 3 - a rotor assembly; 4 - rear bearing; 5 - the bearing retainer; 6 - the front bracket of the generator; 7 - the front cover; 8 - a stator; 9 - bracket; 10 - the voltage regulator and brush holder; 11 - Brush; 12 - spring brush; 13 - dustproof ring; 14 - rectifier unit; 15 - rear bracket generator
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Dismantling (model capacity of 75 A) Remove the three clamping bolts.
| Fig. 7.20. Removing the front kronshteyga generator
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Insert a flathead screwdriver between the front bracket and the generator stator and acting with a screwdriver as a lever to separate the (down) the front bracket of the generator (Fig. 7.20).
ATTENTION Do not insert a screwdriver too deep, so as not to damage the stator winding. |
| Fig. 7.21. Rear bearing assembly with a soldering iron
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It may be that the removal of the rear bracket of the generator will be difficult, because prevents the retaining ring used to secure the rear bearing. To facilitate the removal of the rear bracket heat the bearing assembly using a soldering iron 200 W (Fig. 7.21).
Do not use a heat gun to heat, as this may damage the rectifier diodes. Fix the rotor in a vise so that the side with the pulley facing up.
ATTENTION Make sure that the jaws do not damage the rotor. |
Remove the pulley nut, remove the spring washer, then remove the pulley and the spacer. Remove the front bracket of the generator, and two sealing rings. Remove the rotor from the grip.
| Fig. 7.22. Removing the nut output "B" of the generator
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Remove the screws that secure the brush holder and the rectifier unit. Then unscrew the nut output "B" of the generator (Fig. 7.22). Remove the stator assembly from the rear bracket. Remove the dust ring with the brush holder. Before removing the stator Unsolder three wires of the stator winding of the main diode rectifier unit.
ATTENTION When soldering / desoldering of contacts, be careful that the heat from the soldering iron as little as possible affected the diodes. Perform these operations as quickly as possible. Be careful not to apply force to the contact diodes.
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| Fig. 7.23. Places solder contacts the brush holder
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Before disconnecting the rectifier unit from the brush holder Unsolder two contacts soldered to the rectifier unit (Fig. 7.23).
Check rotor
| Fig. 7.24. Check for the closed circuit between the contact rings
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Check the continuity in the rotor winding. Check the closed circuit between the contact rings (Fig. 7.24). If the resistance is too small (tends to 0), it indicates the presence of a short circuit. In the case of an open circuit rotor winding or a short circuit, replace rotor assembly. Resistance: approximately 3.1 ohms.
| Fig. 7.25. Check the insulation of the rotor winding to the "masses"
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Check the insulation of the rotor winding to the "masses" (Fig. 7.25). Check the closed circuit between the slip ring and core. In the case of a closed circuit (circuit on "weight"), replace the rotor assembly.
Checking the stator Check the insulation in the stator winding.
| Fig. 7.26. Check for the closed loop between the terminals of the stator windings
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Check the closed circuit between the terminals of the stator winding. If the chain is broken coil (resistance tends to infinity), replace stator assembly (Fig. 7.26).
| Fig. 7.27. Check the insulation on the windings of the "masses"
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Check the insulation of the stator winding on "weight" (not a closed circuit between the stator coil and the core) (Fig. 7.27). If the circuit is closed (resistance tends to zero), replace the stator.
Check the positive terminal of the rectifier unit
| Fig. 7.28. Check the closed circuit between terminal "positive" diodes, rectifier unit and the output of the stator winding
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Use an ohmmeter to make sure that the connection between the output of "positive" diodes, rectifier unit and the output of the stator winding is shorted (resistance is small). Reverse the polarity connection ohmmeter probes and measure the resistance (if the resistance is small, that there is continuity in both directions, so the diode test) (Fig. 7.28). Replace the rectifier unit assembly.
Check the negative terminal of the rectifier unit
| Fig. 7.29. Check the closed circuit between terminal "negative" rectifier diodes and the terminal block of the stator winding
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Use an ohmmeter to make sure that the circuit between the terminal "negative" rectifier diodes and the terminal block of the stator winding is shorted (resistance is small). Reverse the polarity connection ohmmeter probes and measure the resistance (if the resistance is small, that there is continuity in both directions, so the diode test) (Fig. 7.29). Replace the rectifier unit assembly.
Check three diodes, rectifier unit
Check three diodes, connecting an ohmmeter to both terminals of each diode. Each diode circuit has to be closed in only one direction (Fig. 7.30). In the absence of closed loop in both directions (or in the presence of the closed loop in both directions) and the rectifier diode defective block (heat dissipating unit) must be replaced.
Replacement brush
Replace brushes when they wear down to the limit line reached (Fig. 7.31).
Unsolder wire brush and remove brush generator with a spring (Fig. 7.32). Install the spring and the new brush in the brush holder.
Insert the brush so that the brush holder between the edge and the boundary line on the brush was a distance of 2-3 mm (Fig. 7.33). Solder the wire brush to brush holder
Dismantling (model capacity of 90 A) Remove the nut output "B" of the generator and remove the back cover.
| Fig. 7.34. Places solder wire of the stator winding
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Before removing the stator Unsolder four wires of the stator winding of the main diode rectifier unit (Fig. 7.34).
ATTENTION When soldering / desoldering of contact be careful that the heat from the soldering iron as little as possible affected the diodes. Perform these operations as quickly as possible. Be careful not to apply force to the contact diodes. |
Remove the stator assembly from the rear bracket of the generator. Remove the brush holder and the rectifier unit. Remove the four coupling bolts.
| Fig. 7.35. Removing the front kronshteyga generator
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Insert a flathead screwdriver between the front bracket and the generator stator and acting with a screwdriver as a lever to separate the (down) the front bracket of the generator (Fig. 7.35).
ATTENTION Do not insert a screwdriver too deep, so as not to damage the stator winding. It may be that the removal of the rear bracket of the generator will be difficult, because prevents the retaining ring used to secure the rear bearing. To facilitate the removal of the rear bracket heat the bearing assembly using a soldering iron power of 200 watts. Do not use a heat gun to heat, as this may damage the rectifier diodes. |
Fix the rotor in a vise so that the side with the pulley facing up.
ATTENTION Make sure that the jaws do not damage the rotor. |
Remove the pulley nut, remove the spring washer, then the pulley and the spacer (Fig. 7.36). Remove the front bracket of the generator and the O-rings. Remove the rotor from the grip.
| Fig. 7.37. Places solder contacts to the rectifier unit
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Before disconnecting the rectifier unit from the brush holder Unsolder two contacts (plates), soldered to the rectifier unit (Fig. 7.37).
Check rotor
| Fig. 7.38. Check continuity between the slip rings
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Check the continuity in the rotor winding. Check the closed circuit between the contact rings (Fig. 7.38). If the resistance is too small (tends to 0), it indicates the presence of a short circuit. In the case of an open circuit rotor winding or a short circuit, replace rotor assembly. Resistance: approximately 3.1 ohms. Check the insulation of the rotor winding to the "masses."
| Fig. 7.39. Check for continuity between slip ring and core
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Check the closed circuit between the slip ring and core (Fig. 7.39). In the case of a closed circuit (circuit on "weight"), replace the rotor assembly.
Checking the stator
| Fig. 7.40. Check the closed circuit between the terminals of the stator windings
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Check the insulation in the stator winding. Check the closed circuit between the terminals of the stator windings (Fig. 7.40). If the chain is broken coil (resistance tends to infinity), replace stator assembly.
| Fig. 7.41. Check the insulation of the stator winding on "weight"
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Check the insulation of the stator winding on "weight" (not a closed circuit between the stator coil and the core) (Fig. 7.41). If the circuit is closed (resistance tends to zero), replace stator assembly.
Check the positive terminal of the rectifier unit
| Fig. 7.42. Check the closed circuit between terminal "positive" diodes, rectifier unit and the output of the stator winding
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Use an ohmmeter to make sure that the connection between the output of "positive" diodes, rectifier unit and the output of the stator winding is shorted (low resistance) (Fig. 7.42). Reverse the polarity connection ohmmeter probes and measure the resistance (if the resistance is small, that there is continuity in both directions, the diode is broken). Replace the rectifier unit assembly.
Check the negative terminal of the rectifier unit
| Fig. 7.43. Check the negative terminal of the rectifier unit
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Use an ohmmeter to make sure that the circuit between the terminal "negative" rectifier diodes and the terminal block of the stator winding is shorted (low resistance) (Fig. 7.43). Reverse the polarity connection ohmmeter probes and measure the resistance (if the resistance is small, that there is continuity in both directions, the diode is broken). Replace the rectifier unit assembly.
Check three diodes, rectifier unit
| Fig. 7.44. Check three diodes, rectifier unit
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Check three diodes, connecting an ohmmeter to both terminals of each diode. Each diode circuit has to be closed in only one direction (Fig. 7.44). In the absence of closed loop in both directions (or in the presence of the closed loop in both directions) and the rectifier diode defective block (heat dissipating unit) must be replaced.
Assembly The assembly is carried out in reverse order. Pay attention to the following:
before installing the rotor in the rear bracket, insert a thin wire into the small hole in the bracket to secure the raised brush (Fig. 7.45). Remove the wire after installing the rotor.
Setting Install the generator in place and insert the bolt hinge (do not tighten the nut bolt hinge).
Push the generator on and determine how many spacers (each 0.198 mm thick) must be inserted between the front desk and the front cover of the generator engine (clearance "A" in Figure 7.46). Choose an amount of shims so that they do not fall when trying to insert them into the gap.
| Fig. 7.47. Vetilyatsionnoe hole in the lid of the battery
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Insert the spacers (the gap "A" in Figure 7.47), connect and tighten the nut bolt hinge to complete the installation.
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