Contents: Disassembly and assembly of the…↓ Replacing the brush holder ↓ Replacing rotor bearings ↓ Replacing additional diodes of…↓
Disassembly and assembly of the generator
Loosen the screws and remove the brush holder 1 (Fig. 231) together with the regulator 21 and the capacitor 19. Loosen the nuts of the tie bolts 13 and remove the generator cover 10 together with the rotor. Clamp the rotor in a vice, loosen the pulley nut and use puller 02.7823.9504 to remove the pulley from the rotor shaft. Remove the woodruff key from the groove on the shaft and remove cover 10.
Fig. 231. Details of the G-222 generator:
1 - brush holder; 2 - neutral wire plug socket; 3 - insulating bushings of the contact bolt; 4 - rectifier block; 5 - contact bolt: 6 - stator; 7 - rotor; 8 - washer; 9 - inner bearing mounting washer; 10 - drive side cover; 11 - pulley; 12 - outer bearing mounting washer; 13 - tension bolt; 14 - rotor bearing; 15 - pressure sleeve; 16 - cover from the contact ring side; 17 - buffer bushing; 18 - bushing; 19 - capacitor; 10 - base; 21 - voltage regulator; 22 - casing.
The 02.7823.9504 puller consists of two steel half rings that are inserted into the pulley groove and a regular puller. The puller jaws grip the half rings and the bolt rests against the end of the generator shaft. The half rings have the same cross-section as the generator drive belt. On one side they are connected by a hinge, and on the other they are equipped with levers that are squeezed by hand when removing the pulley.
Loosen the nuts of the screws connecting the valve tips to the stator winding terminals, remove the zero drive plug from block 2 and remove stator 6 from generator cover 16. Loosen the nut of contact bolt 5 and remove the rectifier unit.
The 37.3701 generator is disassembled in the same order. First, disconnect the wire from the "B" plug of the voltage regulator. Then disconnect the wires of the regulator and capacitor from the "30" terminal of the generator and unscrew the screws securing the voltage regulator. In order not to break the brushes when removing the brush holder, insert a screwdriver blade between the regulator body and the brush holder and partially pull the regulator out of the generator, leaving the brush holder in place. After that, tilt and remove the regulator together with the brush holder from the generator. Remove the capacitor by unscrewing the fastening screw. Further disassembly of the 37.3701 generator is similar to disassembly of the G-222 generator.
The generator is assembled in the reverse order. The misalignment of the holes in the generator cover legs should not exceed 0.4 mm. Therefore, during assembly, it is necessary to insert a stepped cylindrical control mandrel into these holes, having a diameter of 12 mm on one side and 22 mm on the other. The conical spring washer of the pulley should touch the nut with its convex side. Tighten the pulley nut with a torque of 3.9-9.0 kgf·m.
When assembling the 37.3701 generator, to avoid breakage of the brushes, before installing the regulator with the brush holder in place, do not insert the brush holder completely into the regulator, but only partially push it in and insert it into the generator in this form. After installing the brush holder in place in the generator cover, lightly press on the regulator and push it into the generator.
Replacing the brush holder
If the brushes are worn out and protrude from the brush holder by less than 5 mm, replace the brush holder with brushes. Before installing the new brush holder in place, blow out the socket in the generator from carbon dust and wipe off oil mixed with carbon dust.
Replacing rotor bearings
To remove a faulty bearing from the drive-side cover, unscrew the nuts of the screws that hold the bearing mounting washers, remove the washers with the screws, and press out the bearing using a hand press. If the nuts do not unscrew, (the ends of the screws are pierced), then cut off these ends.
Information taken from the website vazbook.ru
A new bearing can be installed in the generator cover only if the bearing hole is not deformed. The diameter of the hole should not be more than 42 mm. If the hole has a larger diameter or is deformed, replace the cover with a new one.
Press the bearing into the cover using a press and then clamp it between two washers, tightened with screws and nuts. After tightening the nuts, punch out the ends of the screws.
When replacing the rotor bearing on the slip ring side, replace the cover at the same time, because if the bearing is damaged, the socket in the cover is also damaged.
Replacing additional diodes of generator 37.3701
To replace, unsolder the leads of the damaged diode and carefully remove it from the plastic holder, avoiding sharp blows to the rectifier unit. Then clean the diode installation site from the remains of epoxy resin, install and solder the new diode. The diode lead with the color mark is soldered to the valve leads. After soldering, glue the diode body to the holder with epoxy resin.