CH-1

Charging device
Page

Structure drawing /electrical schematic diagram of generator.....................CH-2

Inspection on vehicle .......................................................... .....................CH-5

Disassembly of AC generator...................................................................CH-7

Inspection on AC generator......................................................................CH-9

Assembly of AC generator.....................................................................CH-12

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CH-2 Structure drawing /electrical schematic diagram of generator

Structure drawing /electrical schematic diagram of generator

1. Brief description of working principle for generator
That the stator coil of generator goes across the rotating magnetic field produced by the rotor makes the
statorproduce a 3-phase AC current, which will be transformed into DC current by rectifier bridge for a
power supply to electrical devices on vehicle.
2. Structure drawing of generator

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Name of spare parts indicated in the drawing is given below:
1.nut 2.spring washer 3.belt pulley 4.through bolt 5.limiter ring 6.driving end cover 7. bearing
8. bearing cove 9.limiter ring 10.rotor 11.stator 12.adjustor 13.insulation bush 14.nut 15.compensation
bush 16.brush end cover 17. rectifier bridge 18.screw 19.screw 20.screw
 Structure drawing /electrical schematic diagram of generator CH-3

3. Electrical schematic diagram of generator

(a) Circuit schematic diagram for 90A internally-adjusted generator

Electrical schematic diagram

stator coil

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excitation coil
I·C adjustor

(b) Circuit schematic diagram for 90A externally-adjusted generator

Electrical schematic diagram

stator coil

excitation coil
I·C adjustor
CH-4 Structure drawing /electrical schematic diagram of generator

(c) circuit schematic diagram for 65A internally-adjusted generator

Electrical schematic diagram

stator coil

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excitation coil
I·C adjustor

(d) circuit schematic diagram for 65A externally-adjusted generator

Electrical schematic diagram

stator coil

excitation coil
 Charge device-Inspection on vehicle CH-5

Inspection on vehicle
1. Check the specific gravity of accumulator
(a)Check the specific gravity for each accumulator unit. Standard
upper liquid specific gravity when charged with full power at 20 (1.25~1.27)g/cm2
(b)Check the electrolyte amount for each accumulator unit.
level
In case of an insufficient electrolyte amount, fill with distilled or pure
water.

lower liquid level

2. Check the fuse and wiring terminal for accumulator

(a)Check whether the wiring terminal of accumulatorhas been tightened
or corroded;
(b)Check whether the fuse is switched into conduction.

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3. Check the driving belt
(a)Verify by avisual check whether the bonding positionbetween upper/
lower interlayer has any crack or damage; whether any crack, broken
core, rupture, scratch, or abrasion is produced on the edge of belt;or whe
ther any damage is produced on the internal convexity side of reinforced
rib.

(b)Check the bending deflection of belt by applying a 98N stress to the

position indicated in “Stressdiagram”.
Bending deflection of driving belt
New belt (5 7) mm
U s ed bel t 7 8 mm
T he bending deflection of belt may be adjusted when necessary.

(c)The tension of driving belt may also be checked using SST.

SST 09216-00020 and 09216-00030
T ension of driving belt
N ew belt (686 786)N
U sed belt (294 441)N
T he tension of belt may be adjusted when necessary.
CH-6 Charge device-Inspection on vehicle

Note
-The so called new belt r efer s to belt having wor k ed for less
than five minutes on the r otating engine.
-T he so called used belt r efer s to belt having wor ked for five
minutes or above on the r otating engine.
-F ollowing the installation of belt, check whether the belt is
correct incorrect matching with wheel gr oove appr opr iately.

4 . Verify by visual check the connection line of A C

generator, and whether there’s any abnormal noise.
(a)Check whether the connection line is under a normal condition.

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(b)Check whether there’s any abnormal noise on AC generator while the
engine is running.

5. Check the loop for charging alarm indicator lamp.

(a)Heat the engine, then stop it.
(b)Stop all auxiliary devices.
(c)After opening the ignition switch, check whether the charging indictor
lamp has been lighted up.
(d)When the engine is starting, check whether the charging indictor lamp
is off.
(e)If the alarm lamp is not working well, try to eliminate any failure in the
Charge device.

6. Check the charging loop when under zero load

remove electrical wire
ammeter Note
from terminal
If accumulator/AC generator test meter is applicable, the meter shall be
connected into the charging loop in accordance with the description
provided by the manufacturing plant.
(a)If the meter is not applicable, the voltmeter and ammeter shall be
voltmeter connected into the charging loop as per methods below:
battery AC generator -Remove electrical wire from the terminal B on AC generator, and connect
the negative test head of ammeter.
-Connect the positive test head of ammeter to the terminal B on A C
generator.
-Connect the positive test head of voltmeter to the terminal B on A C
generator.
-Connect the negative test head of voltmeter to ground.
Charge device-Inspection on vehicle CH-7

(b)Check the charging loop using following method

When the engine is increased from idle speed to 2000r/min, check the read
value on ammeter and voltmeter.
standard current 10A
standar d voltage (13.9-15.1)V when at 25
(13.4-14.4)V when at 11.5
If the voltage value is greater than standard value IC adjustor needs to
be changed.

If the voltage value is less thanstand ardvalue IC adjustor and AC generat

or must be checked using followin gmethod:
- Check the voltage value of terminal B when terminal F is grounded and
the engine is started.

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-If the voltage value is greater than standard value IC adjustor needs to be
changed.
-If the voltage value is less than standard value AC generator needs to be
changed.

7. Check the charging loop when under load.

(a)Open the front headlight when engine is at a rotatingspeed as 2000
revolutions /minute, and place the control switch of heater fan to shift
position H I .
(b)Check the read value on ammeter.
Standard current >30 A

AC generator needs to be repaired if current value is less than 30A.

Note: Read value might be less than 30A when the
accumulator is charged with full power.
CH-8 Disassembly of AC generator

Disassembly of AC generator
1. Dismantle the assembly of driving end shell and rotor
from the stator.
(a)Remove three through-screws.

(b)When the end shell is prized up by a screwdriver, have it removed

simultaneously with the rotor.
Note: Don’t pry the wire of the coil.

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2. Removal of belt pulley and fan
(a)Fix the rotor onto a soft-jaw vice.
(b)Remove nuts and spring washers.
(c)Remove the belt pulley, fan, and spacer bush.

3. Removal of rotor
Use a press tool to press out the rotor.

4. Removal of rectifier shell

(a)Remove four nuts, capacitor, and two terminal insulators.
(b)Remove the rectifier shell.
(c)Remove two insulation washers from the stud bolt on rectifier support.
(d)Remove the insulation washer from the electrical-brush frame.

lead-wire grip
 Inspection on AC generator CH-9

5. Removal of IC adjustor
When the terminal of IC adjustor is gripped using nipper pliers,remove it by
welding.

6. Removal of rectifier support

When the terminal of IC adjustor is gripped using nipper pliers remove th e
lead wireby welding.
Note M easur es shall be taken to pr event the r ectifier fr om
damage r esulting fr om bur ning.

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Inspection on AC generator R otor
1. C heck whether the r otor is in an open cir cuit.
Use an ohmmeter to check the conduction between slip rings.
Standard resistance 4
T he rotor needs to be changed if non-conduction exists.

conduction

2. Check whether the rotor has been grounded.

Use an ohmmeter to check the non-conduction between slip ring and the
rotor.
The rotor needs to be changed if conduction exists.

non-conduction

3. Check the slip ring

(a)Check whether the surface of slip ring is rough, or has been scratched or
damaged.
If it does occur, the rotor needs to be changed.
(b)The diameter of slip ring shall be measured using calipers.
Standard diameter (32.3 32.5)mm
Min. diameter 32.1 mm
If the diameter is less than Min. value, the rotor needs to be changed.
CH-10 Inspection on AC generator

Stator
1. Check whether the stator is in an open circuit.
Use an ohmmeter to check conduction between leading of the coil.
Note I nter sectant lines must be welded well.
T he stator needs to be changed if non-conduction exists.

conduction

2. Check whether the stator has been grounded.

Use an ohmmeter to check whether noncon duction exists between the coil
leadin and the stator.
If conduction exists, the stator may be changed.

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non-conduction

Electrical-brush
1. Check the exposed length of electrical-brush.
Use a ruler to measure the exposed length of electrical brush.
Standard exposed length 12.5 mm
M in. exposed length 5.5 mm
T he electrical-brush needs to be changed if the exposed length is less than
Min. value.

2. The electrical-brush may be changed when necessary.

(a)Remove the electrical-brush and spring by welding.

(b)Have the electrical-brush line inserted via spring.

(c)Connect the electrical-brush onto the electrical-brush frame.
(d)Weld the electrical-brush line to the electrical-brush frame as per the exposed
length specified below:
Exposed length 12.5 mm
(e)Check whether the electrical-brush may act smoothly inside the electrical-
brush frame.
(f)Cut off excessive electrical wire.
 Inspection on AC generator CH-11

Rectifier
1. Check the positive rectifier
rectifier terminal (a)Using ohmmeter, connect one end of the test head with the rectifier
terminal, and connect the other end with the positive terminal.
(b)Exchange the test joint, and repeat the above step.
ohmmeter (c)Check its conduction or non-conduction covered in above two steps.
(d)The rectifier support shall be changed when its conduction or non-conduction
does not conform to relevant stipulations.

positive terminal (stud bolt cap)

2. Check the negative rectifier

(a)Using ohmmeter, connect one end of the test head with the rectifier terminal,
rectifier terminal and connect the other end with the negative terminal.
(b)Exchange the test joint, and repeat the above step.
(c)Check its conduction or non-conduction covered in above two steps.
(d)The rectifier support shall be changed when its conduction or non-conduction
ohmmeter

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does not conform to relevant stipulations.

negative terminal stud bolt cap

Bearing
1. Check the front bearing
Check whether the bearing is smooth or has been abraded.

2. Change the front bearing when necessary.

Change the bearing by removing three screws.

3. Check the rear bearing.

Check whether the bearing is smooth or has been abraded.
CH-12 Assembly of AC generator

4. Change the bearing when necessary.

(a)Remove the bearing using SST.
SST 09286-46011

(b)Use a press tool to press the new bearing.

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Assembly of AC generator
1. Install the rectifier support onto the stator.
Clamp the rectifier terminal using nipper pliers, and weld the wiring terminal.
Note: the heat shall be prevented from transmission to
rectifier.

2. Installation of IC adjustor
Clamp the rectifier terminal using nipper pliers, and weld the wiring terminal.
Note: the heat shall be prevented from transmission to
rectifier.

3. Installation of the rectifier end shell onto rectifier support

insulation washer (a)Put the insulation washer on the positive stud bolt of the rectifier frames
(b)Put two soft cushions on the electrical-brush frame and AC generator
terminal respectively.
(c)Put the rectifier shell onto the rectifier frame.

soft cushion
 Assembly of AC generator CH-13

(d)Put two terminal insulators onto the positive stud bolt of the rectifier
frame.
(e)Install the capacitor and the lead-wire grip.
(f)Install four nuts.
(g)Confirm that electrical wire has not been overlapped with the rectifier
shell.

lead-wire grip

4. Installation of rotor
(a)Insert spacer ring into the rotor shaft.

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(b)Use press tool to press rotor into the shaft.

5. Installation of fan and belt pulley

(a) Fix the rotor onto soft-jaw vice.

(b) Insert spacer ring into the rotor shaft.

(c)Insert the fan, belt pulley, and spring washer successively into the rotor
shaft.
(d)Install and tighten the nut.
Tightening moment 62.5N m
CH-14 Assembly of AC generator

6. Assembly of the driving end shell and rectifier end shell

(a)Have the rotor exposed by bending the wiring head of rectifier.

(b)Bending tools may be used to push the electrical-brush to the end, then
one hard steel wire shall go through the manhole of rectifier end shell, and the
electrical-brush will be put to place.

(c) Following the insertion of the rear bearing for rotorshaft into the rectifier
end shell, the rectifier shell for driving end shell may be assembled.

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(d)Three through-screws may be installed.
(e)Remove the hard steel wire from manhole.

(f)Check whether the rotor is able to rotate flexibly.

(g)Seal the manhole.