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Dismantling, check and assemblage of the generator (2.4 L)
Dismantling Remove the four coupling bolts. 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.
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.
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Do not use a heat gun to heat, as this may damage the rectifier diodes (Fig. 7.26).
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 (Fig. 7.27). Remove the front bracket of the generator, and two sealing rings. Remove the rotor from the grip. Remove the screws that secure the brush holder and the rectifier unit. Then unscrew the nut output "B" of the generator. 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.
Before disconnecting the rectifier unit from the brush holder Unsolder two contacts soldered to the rectifier unit (Fig. 7.28).
Check rotor
| Fig. 7.29. 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. 7.29). If the resistance is too small (approaches 0), it means that there is 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. 7.30. Check the insulation of the rotor winding to the "masses"
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Check the insulation of the rotor winding to the "masses." Check the closed circuit between the slip ring and core. In the case of a closed circuit (circuit on "weight"), replace the rotor assembly (Fig. 7.30).
Checking the stator
| Fig. 7.31. Check for the closed loop 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 winding. If the chain is broken coil (resistance tends to infinity), replace stator assembly (Fig. 7.31).
| Fig. 7.32. 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). If the circuit is closed (resistance tends to zero), replace stator assembly (Fig. 7.32).
Check the positive terminal of the rectifier unit
| Fig. 7.33. Check the positive terminal of the rectifier unit
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| Fig. 7.34. Check the negative terminal of the rectifier unit
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Using an ohmmeter, check 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, the diode test) (Fig. 7.34). Replace the rectifier unit assembly.
Check the negative terminal of the rectifier unit Using an ohmmeter, check 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, the diode test) (Fig. 7.34). 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. 7.35. Check three diodes, rectifier unit
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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 (together with the radiator cooling) must be replaced (Fig. 7.35).
Replacement brush
Replace the brush when the brush has reached the wear limit line. Boundary line: 2 mm (Fig. 7.36). Unsolder wire brush and remove brush generator with a spring. Solder the wire brush to brush holder.
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 back bracket to fix the raised brush. The wire must be removed after installing the rotor (Fig. 7.37).
Battery Description Maintenance-free battery, as the name implies, requires no maintenance and has no vent plugs battery cans. There is no need to add water to the electrolyte maintenance-free battery. The battery is completely sealed, except for a small vent hole in the lid.
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