Maintenance

With service 2:

- clean external surfaces from dust and dirt;

--- check and, if necessary, adjust the tension of the alternator drive belts. With normal tension of the belts, the deflection boom should be within 15 ... 22 mm when pressing the middle of the larger branch with a force of 39.2 N (4 kgf). To adjust the tension of the belts, loosen the nuts securing the front and rear legs of the generator and the bolt securing the generator to the tension bar. Then deflect the generator towards the belt tension to the required value and tighten the fasteners of the generator

- remove the ball bearing from the shaft;

- remove the rectifier unit from the cover on the side of the slip rings.

After disassembly, clean the generator parts and assembly units from dirt, metal, except for bearings and assembly units containing windings, insulating parts and semiconductor devices, degrease, rinse with gasoline and dry, and wipe the rest with a cloth soaked in gasoline. Inspect and replace mechanically damaged parts. Cracks passing through the hole, wear of the hole more than 17.02 mm and chips of the pulley edges are not allowed on the pulley. more than 2 mm. Check the wear of the belt pulley groove.

The pulley is allowed to be installed if, when installed in the groove of control rollers with a diameter of 14 mm, the diameter measured on the rollers is not less than 83.5 mm (see Fig. 338).

Remove bent fan blades by straightening and straightening.

If the holes in the cover fixing bracket on the side of the slip rings and the cover on the drive side are worn or oval, more than 10.3 mm, drill the hole.

A worn bore for the bearing in the cover on the side of the slip rings to a diameter of more than 35.02 mm, and in the cover on the drive side - more than 47.05 mm, process it to a size of 38.0 ... 38.05 mm and 50.00 .. .50.05 mm, respectively, and then press in the repair ring keeping the same bore size for the bearing.

When assembling the alternator, insert a tight fitting rod into the holes of the alternator mounting on the engine before reassembling to ensure the alignment of the alternator mounting holes on the engine. After tightening the tie bolts, remove the rod.

After assembly, check by hand the ease of rotation of the shaft and the technical condition of the generator.

Checking the rotor field winding. Check the integrity of the winding with a tester (ohmmeter), while making sure that the tips of the measuring wires of the device are in contact with the slip rings of the rotor. The resistance value must correspond to the value specified in the technical characteristics of the generator, if the winding does not have short-circuited turns. If there is a break in the winding, then the ohmmeter needle does not deviate. The serviceability of the winding and the reliability of the adhesion of the brushes to the slip rings can be checked at the stand without disassembling the generator. The test scheme is shown in Fig. 340. When the voltage of the DC power supply is 28 V, connected to the plugs of the winding, the value of the consumed current must not exceed the value specified in the technical characteristics of the generator. If there is an open circuit in the winding,ÒÎ the ammeter needle will not deviate.

Determine the short circuit of the excitation winding to ground with a test lamp or a voltmeter at a voltage of 220 ... 250 V. If there is no current for 1 minute, then the insulation of the winding is in good order.

If an open circuit is found in the field winding, inspect the soldering points of the ends of the winding to the slip rings and, if unsoldering, restore

Rice. 340. Connection diagram for checking the technical condition of the generator

Construction machinery and equipment, reference book

Kamaz Ural cars

Generator design and operation

The generator is designed to operate in a single-wire circuit of the vehicle's electrical equipment. On KamAZ 740 engines, a G288 generator is installed, which works with a voltage regulator 11.3702, or a G273-A generator set.

The G288 alternating current generator (Fig. 3.2) with electromagnetic excitation is a three-phase twelve-pole electric machine with a built-in rectifier on six silicon diodes. The rated power of the generator is 1000 W, the rated voltage is 28 V, the rectified current is not less than 47A. The generator has the following terminals: "+" - for connecting the batteries and the load, "-" - for connecting to the "ground" of the car, "Ш" - for connecting to the "VK" terminal of the instrument and starter switch and the "I /" terminal voltage regulator.

The G273-A alternating current generator set consists of a generator, a built-in rectifier unit and an integral voltage regulator Ya-120M. Its nominal voltage is 24 V, the nominal power is 800 W. The “+” terminal is used to connect the battery and the load, and the “B” terminal is used to connect to the “VK” terminal of the instrument switch and starter.

A seasonal adjustment switch is installed on the voltage regulator, which is carried out as follows: if the outside temperature is stable at 0 ° C and above, the screw is turned to the extreme left position, if the outside temperature is set at 0 ° C and below, the screw is turned to the extreme right position ...

Rice. 3.3. Generating set: 1 - pulley; 2 - fan; 3, 8 - covers; 4 - stator; 5 - rotor; 6 - rotor shaft; 7 - rectifier unit; 9 - contact ring; 10- bearing cover; 11 - make-up resistance; 12 - voltage regulator; 13 - brush assembly

Rice. 3.4. Connection diagram of current sources: О, I, I, III - key position of the instrument switch and starter; IV- to the switch of the electric torch device; V- to the instrument and starter switch; VI - to the starter retractor relay; VII - to the heater electric motors; VIII - to the reversing lights; IX - to the thermostat of the electric torch device; 1 - generator G272; 2 - contactor; 8-button switch "mass"; 4- power switch VK.860; 5 - rechargeable batteries; 6- starter relay PC530; 7 - ammeter; 8 - switch of instruments and starter VK353; 9 - fuse box; 10- relay-regulator PP356; 11-relay for disconnecting the excitation winding of the generator; H - black; B - white; 3 - green; F - yellow; K - red; F - purple; Brown cortex; O - orange

The generator consists of a stator, rotor, covers, rectifier unit, brush assembly. The field winding is located on a shaft that rotates on two ball bearings. At one end of the shaft, a fan and a double-ribbed pulley are fixed, at the other there are slip rings connected to the excitation winding, along which the brushes slide. The cover contains a rectifier unit and a brush holder.

The non-contact voltage regulator automatically maintains the voltage of the generator within the limits that ensure the charging of the batteries and the reliable operation of consumers.

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Generator Kamaz

1. Do not connect or disconnect the plugs and the positive terminal of the generating set with the engine running and the batteries on, and do not start the engine when

the positive wire disconnected from the generator.

2. Do not check the generator set for serviceability by shorting the terminals “+”, B, O with jumpers to ground and between themselves.

3. Do not connect the lead Ш of the brush holder, which is accessible through the window in the casing of the brush holder, with the leads “+” of the generator, B of the brush holder. This leads to failure of the regulator.

4. Do not check the serviceability of the electrical circuit and individual wires with a megohmmeter or a lamp supplied with a voltage higher than 36 V. If such a check is necessary, then first disconnect

wires from the generator set.

5. To avoid damage to the rectifier unit and voltage regulator when recharging batteries from an external source, disconnect the batteries from the vehicle's mains. When washing a car

protect the generator from water ingress.

Maintenance

With service 2:

Clean external surfaces from dust and dirt;

Check and, if necessary, adjust the tension of the alternator drive belts. With normal tension of the belts, the deflection boom should be within 15 ... 22 mm when pressing the middle of the larger branch with a force of 39.2 N (4 kgf). To adjust the tension of the belts, loosen the nuts securing the front and rear legs of the generator and the bolt securing the generator to the tension bar. Then deflect the generator towards the belt tension to the required value and tighten the fasteners of the generator

During service C (autumn), after removing the generator from the engine:

Check the condition of the brush assembly;

Blow out the rectifier unit with compressed air;

Check the reliability of the pulley attachment to the generator shaft, tighten when loose.

To check the condition of the brush-collector unit, unscrew the two bolts securing the brush holder in the cover, remove the brush holder and make sure that the brushes move freely in the guides.

If the brush sticks in the brush holder, wipe it and the walls of the guide hole with a cloth soaked in gasoline. Remove the brushes, inspect and measure their height. The height of the brush must be at least

8 mm from spring to brush base. Replace brushes if necessary. Disassembly of brushes is not allowed.

Slip rings are clearly visible through the hole in the cover, in which the brush holder is located. Inspect the condition of the slip rings and, if necessary, wipe with a cloth soaked in petrol.

If after that burns or dirt are found, then clean the rings with a strip of C100 glass skin, pressing it to the rings through the hole in the cover for the brush holder and turning

generator rotor.

Grind slip rings if burn-on cannot be removed, rings have an uneven surface or wear more than 0.5 mm in diameter. The minimum allowable groove diameter of slip rings is 29.3 mm.

Before removing the cover from the side of the slip rings, remove the brushes together with the brush holder to avoid damage to the brushes.

Seasonal adjustment is carried out as follows:

If the outside temperature is stable at a level of 0 ° C and above, the PPR (seasonal adjustment switch) should be in the SUMMER (L) position - left extreme position

contact screw PPR, screw is removed;

If the outside temperature is stable at 0 ° C and below, the PPR should be in the WINTER position (3) - the right extreme position of the PPR screw, the screw is screwed in.

Regulated voltage level of the generator in the PPR SUMMER position at a load current of 20 A, a rotational speed (3500 + 200) min-1, an ambient temperature of (25 + 10) ° C and a switched off battery

the battery should be within 27 ... 28 V, and in the PPR WINTER position - 28.8 ... 30.2 V.

To remove the generator, disconnect the mass of the batteries, lift the cab and disconnect the terminals “+”, “-”, B. Loosen the clamping bolt of the split support of the generator bracket, then unscrew the nut of the stud fastening the generator to the bracket, unscrew the bolt securing the generator to the tension bar and remove the generator ...

To install the generator on the bracket, insert the generator pin into the split support, and the bracket pin into the hole in the front cover of the generator, put on the spring washer and screw the nut onto the hairpin by hand. Install the drive belts on the alternator pulley, ensuring that the axes of the grooves of the alternator pulley and the engine pulley coincide within ± 1 mm. Ensure the alignment of the axes by moving the generator. Put a spring washer on the bolt securing the generator to the tensioning bar, align the holes in the bar and the generator cover and screw in the bolt, setting the required tension on the drive belts by moving the generator.

Tighten the bolt securing the generator to the bar, tighten the nut securing the generator to the bracket stud and tighten the tie bolt of the generator split support. To avoid breakage of brackets

the generator, follow the procedure for tightening the fasteners.

Connect pins “-”, “+” and B.

When repairing a generator, it is recommended to troubleshoot faults by replacing damaged parts and assembly units, and for this it is not always necessary to completely disassemble the generator. Allowed

repair of individual parts.

To disassemble the generator:

Unscrew the bolts securing the brush holder to the cover and remove the brush holder assembly with a voltage regulator;

Remove the screws securing the ball bearing cover;

Remove the clamping screws securing the generator cover;

Remove the cover from the side of the slip rings together with the stator;

Disconnect the phase leads of the stator winding from the leads of the rectifier unit and separate the stator;

Unscrew the pulley fastening nut, having previously secured the rotor to one of the poles or holding it with a wrench, and remove the pulley;

Remove the fan, remove the key from the groove and remove the thrust bush;

Remove the cover from the drive side together with the ball bearing from the rotor shaft using a special extractor (fig. 339), using for this purpose the threaded holes in the cover;

Rice. 339. Puller

Remove the ball bearing from the shaft;

Remove the rectifier block from the cover on the side of the slip rings.

After disassembly, clean the generator parts and assembly units from dirt, metal, except for bearings and assembly units containing windings, insulating parts and semiconductor devices, degrease, rinse with gasoline and dry, and wipe the rest with a cloth soaked in gasoline. Inspect and replace mechanically damaged parts. Cracks passing through the hole, wear of the hole more than 17.02 mm and chips of the pulley edges more than 2 mm are not allowed on the pulley. Check the wear of the belt pulley groove.

The pulley is allowed to be installed if, when installed in the groove of control rollers with a diameter of 14 mm, the diameter measured on the rollers is not less than 83.5 mm (see Fig. 338).

Remove bent fan blades by straightening and straightening.

If the holes in the cover fixing bracket on the side of the slip rings and the cover on the drive side are worn or oval, more than 10.3 mm, drill the hole.

A worn bore for the bearing in the cover on the side of the slip rings to a diameter of more than 35.02 mm, and in the cover on the drive side - more than 47.05 mm, process it to a size of 38.0 ... 38.05 mm and 50.00 .. .50.05 mm, respectively, and then press in the repair ring keeping the same bore size for the bearing.

When assembling the alternator, insert a tight fitting rod into the holes of the alternator mounting on the engine before reassembling to ensure the alignment of the alternator mounting holes on the engine. After tightening the tie bolts, remove the rod.

After assembly, check by hand the ease of rotation of the shaft and the technical condition of the generator.

Checking the rotor field winding. Check the integrity of the winding with a tester (ohmmeter), while making sure that the tips of the measuring wires of the device are in contact with the slip rings of the rotor. The resistance value must correspond to the value specified in the technical characteristics of the generator, if the winding does not have short-circuited turns. If there is a break in the winding, then the ohmmeter needle does not deviate. The serviceability of the winding and the reliability of the adhesion of the brushes to the slip rings can be checked at the stand without disassembling the generator. The test scheme is shown in Fig. 340. When the voltage of the DC power supply is 28 V, connected to the plugs of the winding, the value of the consumed current must not exceed the value specified in the technical characteristics of the generator. If there is an open circuit in the winding, ÒÎ the needle of the ammeter will not deviate.

Determine the short circuit of the excitation winding to ground with a test lamp or a voltmeter at a voltage of 220 ... 250 V. If there is no current for 1 minute, then the insulation of the winding is in good order.

If an open circuit is found in the field winding, inspect the soldering points of the ends of the winding to the slip rings and, if unsoldering, restore

Rice. 340. Connection diagram when checking the technical condition of the generator

broken connection. If there is an open inside the winding or a turn-to-turn short circuit or a winding short to ground, replace the rotor.

Check the stator winding separately, after disassembling the generator, with the winding leads disconnected from the rectifier unit.

To determine a break in the stator phase winding, alternately connect two phases of the winding to a tester (ohmmeter) or through a test lamp to a 12 ... 30 V current source. the tester (ohmmeter) does not deviate, and the test lamp does not light up. With a good phase winding, the ohmmeter readings should correspond to the values ​​specified in the technical specification.

Check the turn-to-turn short-circuit of the stator winding with a portable flaw detector PDO-1.

Check the short circuit of the stator winding to ground due to mechanical or thermal damage to the insulation of the winding or terminals with a test lamp under a voltage of 220 ... 250 V by turning on one conductor to the stator core, and the other to one of the winding terminals. If the lamp does not light up, there is no short circuit.

Check the condition of the insulation of the winding wires; the insulation should not show any signs of overheating.

If the phase terminal is cut off from the tip, unwind one or two turns of the winding, install an insulating pipe and press or solder the tip.

Checking the technical condition of the generator. Failures in the generator set can be caused by malfunctions of the generator, voltage regulator, or electrical contact failure in the power supply system circuit. Therefore, before proceeding with the check, make sure that the electrical contact of the wires at the terminals of the generator, the voltage regulator, in the connecting blocks between the wire bundles and that the relay for disconnecting the excitation winding of the generator is in good working order (see electric torch device) is in good working order. Check with a test lamp the presence of current in the excitation circuit.

Check the technical condition on a stand that allows you to change the generator rotor speed, current load and measure voltage, current and generator rotor speed.

Power the field winding from a direct current source. The supply voltage is 28 V. The connection diagram for checking the technical condition of the generator is shown in Fig. 270.

Select measuring instruments so that the measured values ​​are within 30 ... 95% of the scale. The device for measuring the magnitude of the current must have an accuracy class of at least 1.5, and the voltage - 1.0.

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Technical characteristics of the KAMAZ generator, repair and connection diagram

To provide power consumers with power, a generator is installed on the car, KAMAZ can be equipped with a generator that meets the requirements. The article provides a description of the device, provides technical specifications, possible problems, and how to fix them.

[ To uncover]

Description of the device

The generator set is one of the main components of the car. It provides power to the vehicle's single-wire electrical circuit while the engine is running. Its design includes a generator and a voltage regulator (video by yuriy s).

The unit is located in the upper part of the motor in front. It is held by 3 paws. Two of them attach the device to the bracket, the third paw serves as an attachment to the tension bar. Powered by V-belts. They must be of rated voltage, otherwise the device will not work efficiently. Therefore, two belts are installed on KAMAZ trucks.

Principle of operation

The voltage from the battery is transmitted to the field winding thanks to brushes and slip rings, provided that the instrument switch is turned on and the starter is in position "I" or "II". A magnetic field arises around it, due to which a plus and a minus appears on the rotor, corresponding to the south and north poles. When the rotor starts to work, the magnetic flux changes simultaneously with it. It crosses the windings of the stator coils, in which an alternating current occurs, which flows into the rectifier unit. In the block, it becomes permanent.

Functions performed

A battery is required to start the generator set. When the voltage that occurs during the operation of the unit exceeds the battery voltage, the unit will begin to supply power to consumers and charge the battery.

Thanks to the voltage regulator and generator, the voltage of the on-board network is maintained within acceptable limits.

Technical specifications

The G273-A generator set has a rated voltage of 24 V and a power of 800 W. The rated voltage of the G288 generator is 28 V, and the power is 1000 W. The G288 generator is installed on the KAMAZ 5320. There are also other models of generators.

Device components

The main elements of the generator are the stator (2) and the rotor (5). In addition, the design includes covers (8), a brush assembly (1) and a rectifier unit. On 2 ball bearings, the shaft rotates, on which the excitation winding is located. On one end of the shaft there are slip rings, which are connected to the winding, on the other - a fan (6) and a 2-pulley (4). Brushes slide along the rings. The rectifier unit and brushes are located in the cover.

The voltage regulator is equipped with a seasonal switch. At temperatures below zero degrees, the switch occupies the extreme right position, at temperatures above zero - the extreme left.

Major malfunctions and their elimination

Connection Guide

A wiring diagram is required to successfully connect the generating set.

In addition, for the correct operation of the installation, it is necessary to strictly observe its connection according to the terminal diagram:

• the battery and the load are connected to the “+” terminal;
• it is necessary to connect the mass of the car to the “-” terminal;
• output "B" or "W" is intended to be connected to the instrument and starter switch.
• output "W" or "~" is a phase output, to which a tachometer and a relay blocking the starter are connected;
• output "+ D" or "D" from additional diodes for connecting a control lamp.

It is important to make the correct connection, otherwise the components of the car and the generator itself may fail.

The price of the issue

Video "How to connect a KamAZ generator set"

This video demonstrates how to correctly connect a Kamaz generator (video by altevaa TV).

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