"Gazelle" Gas-2705>> Electric equipment>> Electric equipment of cars with engines ZMZ-4025, ЗМЗ-4026>> The generator

Fig. 9.2. The generator: 1 — a bearing cover; 2 — a cover щеткодержателя; 3 — щеткодержатель; 4 — the condenser; 5 — a brush; 6, 13 — covers; 7 — выпрямительный the block; 8 — статор; 9 — a contact ring; 10 — a rotor; 11 — an excitation winding; 12 ball bearing; 14 — the fan; 15 — a pulley




Fig. 9.3. The electric scheme of the generator: 1 — a contact ring; 2 — a brush; 3 — an excitation winding; 4 — a winding статора; 5 — a heat-conducting path plate; 6 — the diode; 7 — the condenser




The generator 161.3701* (fig. 9.2, 9.3) represents the three-phase synchronous electric car with electromagnetic excitation and the built in silicon rectifier. The generator works together with a pressure regulator.

* On a part of cars the generator 191.3771 can be established.

Generator technical characteristics
Rotation direction (from outside a pulley)..... Right
Pressure (nominal), В.... 14
The maximum current, А.... 65
Frequency of rotation of a shaft of the generator at which pressure on plugs 14 is reached In,
At temperature of air and the generator +25 With, mines-1
At a current equal to zero..... 950
At a current of loading 50 А.... 2100
Number of phases статора..... 3
Number of coils in a phase..... 54
Winding статора..... Wire ПЭТ-200, diameter of 1,06 mm
The coil of a winding of excitation..... Wire ПЭТВ-1, diameter of 0,9 mm
Quantity of coils in the coil..... 440+10
Resistance of a winding of excitation at temperature 20 With, the Ohm..... 2,35—2,6
Type of brushes..... M1A
Pressing of springs brushes, Н (кгс)..... 1,9—2,5 (0,19—0,25)
Bearings ball:
In a forward cover..... 6180603К1С9Ш1
     In a back cover..... 61805021К1С9Ш1
The vyprjamitelnyj block..... БПВ 46-60-02 or БПВ 34-60-02
Number of diodes..... 6
Features of maintenance service of the generator
Generator survey begin with brushes щеткодержателя and contact rings. It is necessary to be convinced that brushes are whole, not заедают in щеткодержателях and reliably adjoin to contact rings, to check up pressing of springs brushes. The brushes which have been worn out to 8 mm, are subject to replacement.

Fig. 9.4. Check of effort of springs of brushes




For gauging of pressing of springs on brushes to remove one brush, to establish a cover in щеткодержатель and to keep her hand. Acting from щеткодержателя the brush end to press on a cup стрелочных scales (fig. 9.4). When the brush will act from щеткодержателя on 2 mm, notice indications of scales. The same to repeat with the second brush.
The generator to blow compressed air. Щеткодержатель brushes and slightly polluted contact rings to wipe the pure napkin moistened in gasoline.
Strongly polluted contact rings with small подгоранием and small roughnesses should be smoothed out (having removed щеткодержатель) a glass paper granularity 80 or 100, rotating an anchor a hand. To apply for this purpose наждачную a skin it is forbidden. The rings worn out, burnt slightly or having raised palpation pierce on a lathe.
Generator repair
For generator removal:
— To disconnect the storage battery from an onboard network of the car;
- To disconnect wires from the generator;
- To remove a tension lath of the generator;
- To turn the generator towards the block of cylinders of the engine and to remove приводной a belt;
- To turn away bolts of fastening of the generator and to remove the generator.
Dismantling. The generator to assort in a following order:
- To remove щеткодержатель with brushes;
- To uncover the bearing;
— To unscrew coupling screws of the generator and to remove a back cover with статором;
- To disconnect the phase ends of a winding статора from выпрямительного the block and to remove статор;
- To remove from an anchor a pulley, the fan, шпонку and the persistent plug;

Fig. 9.5. Removal of a forward cover of the generator




- To remove from a rotor shaft a forward cover together with the bearing, using carving apertures in a cover and the special adaptation (fig. 9.5).
Check of a condition of details of the generator

Fig. 9.6. Check on absence of short circuit of coils статора on the case




By means of the control lamp included in a network of an alternating current (fig. 9.6) to check up absence of short circuit of coils статора on the case. At check by a control lamp to connect it to any conclusion of a winding статора and the case. Thus tips should not concern cases. The lamp should not to burn. If the lamp burns, it specifies in winding short circuit статора on the case. In this case it is necessary to eliminate damage or to replace статор.

Fig. 9.7. Check of windings статора on chain breakage




Then it is necessary to check up serviceability of windings статора. For this purpose the control lamp is serially connected to two tips of conclusions of a winding статора (fig. 9.7), at a serviceable winding the lamp should burn. If between any two conclusions the lamp does not burn, it specifies in breakage of a winding or on connection infringement in an average point of phases.
Windings статора also should be checked up on absence межвитковых short circuits. Windings should not move in grooves that can lead retyranny of isolation and межвитковому to short circuit.
On internal diameter статора there should be no traces задевания a rotor. At presence задеваний to check up covers and bearings; if necessary to replace them.
At survey to pay attention to absence of damages of covers, especially in the locations of paws of fastening.
Diameter of an aperture under the bearing in a cover from outside contact rings should be (350,012) mm. If diameter of an aperture under the bearing above specified the cover is subject to replacement.
Be convinced that the bearing in a cover from outside a pulley sits densely (прессовая landing). Diameter of an aperture under the bearing should be 47+0,027мм.

Fig. 9.8. Check of resistance of a winding of excitation of a rotor




Fig. 9.9. Rotor check on absence of short circuit of a winding on the case




It is necessary to check up by means of an ohmmeter (fig. 9.8) resistance of a winding of excitation of a rotor which should be 2,35—2,6 Ohm at 20 With, and also on absence of short circuits of a winding on the case (fig. 9.9). In the presence of damages the rotor is subject to replacement.

Fig. 9.10. Зачистка contact rings




If at survey of contact rings of a rotor it is revealed that they are polluted and have traces подгара and non-uniform deterioration on width, rings should be smoothed out a small glass skin granularity 80 or 100. For зачистки rings it is necessary to fix a forward cover in a vice and smoothly turning a rotor, to make зачистку rings a skin, as is shown in fig. 9.10.

Fig. 9.11. Check of palpation of contact rings




If rings have considerable deterioration and the raised palpation of a surface, they should be pierced on a lathe. The roughness of the processed surface of rings should be no more Ra = 0,8. Is minimum admissible diameter проточки contact rings of 29,2 mm. After проточки it is necessary провернть идикатором palpation of rings (fig. 9.11). Palpation of rings above 0,08 mm leads their fast подгоранию and to deterioration of brushes.
To check up, whether заедают brushes in щеткодержателях, and also a condition and size of deterioration of brushes and force of pressing of springs of brushes. By weak pressing of brushes increases искрение and rings burn. Excessive pressing of brushes causes their raised deterioration. Pressing should be within 1,9—2,5 Н (0,19—0,25 кгс). It is necessary to watch, that brushes in щеткодержателях moved freely, without jammings and the increased backlash. Even insignificant jamming of brushes which is sometimes difficult for defining, increases искрение under brushes.
It is necessary to replace 8 mm worn out to height or the damaged brushes new type M1А. To apply brushes of other type it is impossible. Greasy brushes carefully clear and blow compressed air.

Fig. 9.12. The vyprjamitelnyj block: 1 — a positive plate of a heat-conducting path; 2 — the diode with positive polarity on the case; 3 — the diode with negative polarity on the case; 4 — a negative plate of a heat-conducting path




Fig. 9.13. Check of the diode by means of a control lamp: 1 — the diode; 2 — a control lamp; 3 — a source of a direct current 6—12 In




Vyprjamitelnyj block BPV 46-65-02 or БПВ 34-65-02 (9.12) is necessary for clearing fig. of a dirt carefully. To make check of diodes by a control lamp or an ohmmeter. At check it is necessary to consider that in tyres запрессованы diodes of various polarity. At inclusion of the checked diode under the scheme And (fig. 9.13) the lamp should burn, and at inclusion under the scheme In should not to burn. If the specified condition is not carried out, выпрямительный the block is subject to replacement.
More careful check of diodes should be spent by means of the special device for check of semi-conductor devices. After the termination of survey and replacement of defective details the generator should be collected. Generator gathering is made in an order, the return to dismantling. After assemblage it is necessary to make control check of the generator.
Control check is made on the test bed consisting of the electric motor, allowing smoothly to change frequency of rotation of the generator to 3000 mines-1 devices; the resistor, allowing to create loading to 50 And in a chain of the generator, the battery 6СТ-55А and the resistor in a chain of a winding of excitation on 5 A.Mozhno to use control and measuring stand E242.

Fig. 9.14. The scheme of check of the generator at the stand: 1 — a tachometre; 2 — the electric motor; 3 — the generator; 4, 8 — the voltmeter; 5 — the current index; 6, 10 — switches; 7,9 — loading resistors; 11 — the storage battery




The scheme of connection of the generator for test at the elementary stand is shown on fig. 9.14. For generator check it is necessary to include the scheme the switch 10 and the resistor 9 to adjust on the voltmeter pressure 14 V.Bez loadings (the switch 6 is switched off) when the generator cold, the voltmeter 4 should show 14 In at frequency of rotation of a rotor no more than 950 mines-1. Then it is necessary to include the scheme the switch 6 and, increasing frequency of rotation of the generator, to increase loading. At loading 50 And and pressure 14 In (the voltmeter 4) frequency of rotation of a rotor should be no more than 2100 mines-1. During these tests pressure on a conclusion Ш to support the resistor 9 within 14 In (the voltmeter 8).
Generator installation on the engine
For generator installation it is necessary:
- To turn away a nut of fastening of arms of the generator to the block of cylinders;
- To establish the generator and preliminary to fix a forward bolt of fastening. Moving of a forward arm to achieve соосности a pulley of the generator with pulleys of a cranked shaft and the water pump;
- Moving of a back arm to achieve, that between a paw of the generator and an arm there was no backlash;
- To establish a back bolt and a few to tighten it; to fix nuts of fastening of arms to the block;
- To establish a belt and to make its tension by means of a tension lath;
- To make a definitive inhaling of bolts of fastening of the generator.