Generator disassembly
Removing nuts from extension 21 (pic. 7-9) contact bolt and unscrewing the fastening screws, remove the protective cover 19 with the hose. Disconnect the bundle of wires 22.
Pic. 7-9. Generator details: 1 - «negative» brush; 2 - brush holder; 3- «positive» brush; 4 - block of the neutral wire plug; 5 - insulating bushings; 6 - rectifier block; 7 - contact bolt; 8 - stator; 9 - rotor; 10 - inner washer for fastening the bearing; 11 - cover on the drive side; 12 - outer washer for fastening the bearing; 13 - rotor bearing; 14 - coupling bolt; 15 - clamping sleeve; 16 - cover from the side of slip rings; 17 - buffer sleeve; 18 - bushing; 19 - protective cover; 20 - casing fastening screw; 21 - contact bolt extension; 22 - bundle of wires
Loosen the screws and remove the brush holder 2 with brushes.
Unscrew the nuts of the coupling bolts 14 and remove the cover 11 of the generator together with the rotor.
Clamp the rotor in a vice, unscrew the pulley nut and remove the pulley from the rotor shaft with a puller 02.7823.9504. Remove the segment key from the groove on the shaft and remove the cover 11.
Unscrew the nuts of the screws connecting the tips of the valves to the terminals of the stator winding, remove the neutral wire plug from the block 4 and remove the stator 8 from the cover 16 of the generator.
Unscrew the nut of the contact bolt 7 and remove the rectifier unit 6.
Generator Assembly
The generator is assembled in the reverse order of disassembly.
The misalignment of the holes in the paws of the generator covers should be no more than 0.4 mm. Therefore, during assembly, it is necessary to insert a special gauge into these holes.
The convex side of the pulley spring washer must be in contact with the nut. Tighten the pulley nut to a torque of 38.2-61.7 N·m (3.9-6.3 kgf·m).
Brush holder replacement
If the brushes are worn out and protrude from the brush holder by less than 5 mm, then replace the brush holder with brushes.
Before installing the brush holder, blow off coal dust from the installation site and wipe off the oil mixed with coal dust by wiping.
Replacing the rotor bearing on the drive side
To remove the defective bearing from the cover, unscrew the nuts of the screws tightening the bearing fastening washers, remove the washers with screws and press the bearing out with a hand press. If the nuts do not loosen (the ends of the screws are punched), then sleep the ends of the screws.
It is possible to install a new bearing in the generator cover only if the bearing hole is not deformed and its diameter is not more than 42 mm. If the hole has a larger diameter or is deformed, replace the cover with a new one.
The bearing is pressed into the cover on a press and then clamped between two washers tightened with screws and nuts. After tightening the nuts, unscrew the ends of the screws.