10.4.5. Repair of the generator

It will be required to you: screw-drivers with a flat and crosswise edge, keys "on 8", "on 10", face keys "on 8", "on 24", the hammer, a tester.
1. Remove the generator from the car (see. "Removal and installation of the generator").
2. Remove tension regulator (see. "Check and replacement of the regulator of tension with the brush holder").
3. Turn off three nuts of fastening of the vypryamitelny block and two nuts of fastening of remote plugs of the plus plug and the plug of excitement of the generator...
4.... then remove plugs.
5. Unsolder six conclusions of a statorny winding...
6.... also remove the vypryamitelny block from the generator.

Note
So the removed vypryamitelny block from the protection cover looks...
... and so — from the stator.
So the condenser which is fixed looks.

7. Check "negative" diodes, having connected the "positive" (red) probe of a tester to a "minus" plate (tire) of the vypryamitelny block, and the "negative" (black) probe serially to three contact conclusions of diodes in three places (through one) fastenings of windings of the stator. If diodes serviceable, the tester shows 580–620 Ohms.
8. Connect the "negative" (black) probe of a tester to a "minus" plate of the vypryamitelny block, and the "positive" (red) probe serially to the same three contact conclusions. If diodes serviceable, the tester shows infinitely big resistance.
9. If the tester shows resistance, low or close to zero, the diode "is punched" if the indication of a tester aspires to infinitely big resistance irrespective of color of the connected probes, the diode "in break". Both in that and in other case the vypryamitelny block is subject to replacement.
10. Similarly check "positive" diodes, but only rather "plus" plate of the vypryamitelny block or a conclusion "In +" the generator.
11. Check a stator winding tester for lack of break (the scheme with continuous lines) and for lack of short circuit on the starter case (the scheme with dashed lines). When carrying out measurements you watch that conclusions of windings did not concern a generator cover.
12. Mark a relative positioning of covers of the generator...
13.... turn out four coupling bolts...
14.... and, having hooked the screw-driver, uncover the generator from contact rings.
15. Take out the stator from a cover.
16. Examine the stator. On its internal surface there should not be anchor zadevaniye traces about the stator. If there is a wear, it is necessary to replace bearings or covers of the generator.
17. Establish a cap key on a nut and through its opening insert a six-sided key into a shaft opening. Turn off a cap key a nut, holding a shaft from a provorachivaniye.
18. Remove a spring washer and a pulley from a rotor shaft.
19. Take a rotor shaft from the bearing. If necessary screw on a rotor shaft a nut of fastening of a pulley and through a wooden pro-rate easy blows of the hammer to a vypressuyta a rotor shaft from the bearing.
20. Examine a cover from the drive (assembled with the generator bearing).
21. If at rotation of the bearing the side play between rings, a rift or jamming of bodies of swing is felt, protective rings are damaged or is begin to flow lubricants, replace the bearing and if cracks in a cover are found, especially in places of fastening of the generator, it is necessary to replace a generator cover.
22. For replacement of the bearing or a cover turn out four screws of fastening of a persistent washer of the bearing...
23.... also remove a washer.
24. By means of an aluminum pro-rate easy blows of the hammer to a vypressuyta the bearing from a generator cover.
25. Press the new bearing in a cover, using a face head of suitable diameter.
26. Examine contact rings. If on them there are teases, risks, scratches, wear tracks from brushes and other defects, rings need to be proshlifovat. If damages of rings cannot be removed with a skin, pierce rings on the lathe, removing the minimum layer of metal, and then a proshlifuyta.
27. Check a tester rotor winding resistance, having connected it to contact rings. If a tester show infinity, so in a rotor winding the break and it needs to be replaced.
28. Check lack of short circuit of a winding of a rotor for the case, having connected tester conclusions to any contact ring and the case of a rotor. The tester has to show infinity.
29. Check ease of rotation of the bearing from contact rings. If at rotation of the bearing the side play between rings, a rift or jamming of bodies of swing is felt, protective rings are damaged or is begin to flow lubricants, the bearing needs to be replaced.
30. For this purpose a stripper press the bearing from a shaft of a rotor and a napressuyta new by means of a suitable mandrel, putting effort to an internal ring of the bearing.
31. Examine a generator cover from contact rings. At detection of cracks the cover needs to be replaced.

Good advice
Replace all details in specialized workshops or at the official dealer as the cost of spare parts is quite high, and replacement of details is labor-consuming, with use of the professional tool. Besides in these cases the qualified diagnostics is required. After carrying out repair the generator needs to be tested at the diagnostic stand. Such stand imitates real operation of the generator with the varied loadings, at the same time continuous control of tension and current of charging is conducted. On the basis of the received results of check the performer provides a guarantee as on the spare parts acquired and installed to them and for the performed repair and diagnostic work.

32. Collect the generator as it should be, the return to dismantling, having oriented covers of the generator and the case of the stator on early to the made tags.