Generator Safety Precautions
Before doing any work on the charging system, you should familiarize yourself with the following safety precautions:
1. Never disconnect the battery or voltage regulator while the engine and alternator are running.
2. Never short the excitation terminal of the generator or the cable attached to it to ground.
3. Never confuse voltage regulator wires.
4. Never turn on the voltage regulator if it is connected to ground (instant damage).
5. Never remove the generator unless the battery is disconnected from the circuit.
6. When installing the battery, ensure that the negative terminal is connected to ground.
7. Never use a voltage indicator that is connected directly to the household network (110 or 220 V). Use only a 12 V indicator.
8. If the battery is being charged in the installed state by the charger, both battery cables must be disconnected. Connect the positive terminal of the charger to the positive terminal of the battery, and the negative terminal of the charger to the negative terminal of the battery.
9. Incorrect wiring leads to the destruction of the rectifier and voltage regulator.
Checking the installed generator
During normal driving, the charge control lamp should go out. Otherwise, the fault lies in the generator or voltage regulator. First, check the electrical connections of the generator. Check if the drive belt is properly tensioned. A further check can only be carried out with the alternator removed, but all fuses can be checked first.
Servicing, checking and repairing the generator
Note: The generator and regulator are not subject to adjustments and repairs. A non-working generator can be replaced with a replacement one by returning the old generator at the time of purchase.
Service
The generator bearings are long-term lubricated and do not require regular maintenance. Keep the outside of the generator clean and free from water or other solvents.
Check and repair
The alternator brushes slide on smooth slip rings and therefore have a very long service life. Generator removal is not required to check the brushes. Do the following work:
Charger Safety Precautions
Working with the charger requires the following safety precautions:
1. The battery or voltage regulator must not be disconnected while the engine or alternator is running.
2. Do not allow contact with the earth of the terminal of the excitation winding of the generator or the cable attached to it.
3. Never swap the voltage regulator wires.
4. Never turn on the voltage regulator if it is connected to ground (will be damaged immediately).
5. Never remove the alternator without first disconnecting the battery.
6. When installing the battery, make sure that the negative terminal is connected to ground. Although the terminals have different diameters, an error is possible.
7. Never use a test lamp connected directly to the mains (110 or 220 V). Use only a 12 V test lamp.
8. When charging the battery without removing it from the vehicle, both cables must be disconnected. The positive terminal of the charger must be connected to the positive pole of the battery, and the negative terminal to the negative.
9. Incorrect connection of the charger leads to damage to the rectifier and voltage regulator.
10. When replacing, install a generator of the appropriate output current.
Checking the alternator on the engine
During normal operation of the vehicle, the battery discharge indicator lamp should not light. If the lamp is on, then this indicates a malfunction in the generator or voltage regulator.
First, all connections to the generator must be checked.
Check the tension of the V-belt. Other checks are carried out on the generator removed from the engine. It is recommended that they be carried out in a car repair shop with special control equipment.
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