DIY sable generator repair

In detail: do-it-yourself sable generator repair from a real master for the site my.housecope.com.

Gazelle Sable. Removal and disassembly of the generator 3212.3771

Generator 3212.3771 (BATE) is installed on engines ZMZ-405, -406; differs from the generator 9422.3701 (see "Generator", p. 137) by the presence of an additional output from the stator windings and eight power diodes in the rectifier unit. The maximum generator current is 90 A, the nominal voltage is 14 V.

To remove the generator, disconnect the battery.

Generator 3212.3771: 1 - casing; 2 - output "B +" for connecting consumers; 3 - capacitor; 5 - output "W"; b - plates of the rectifier unit; 7, 8 - diode (valve) of the rectifier unit; 9 - voltage regulator; 10 - back cover; 11 - clamping screw; 12 - front cover; 13 - stator winding; 14 - a distance ring; 15 - front bearing of the rotor shaft; 16 - pulley; 17 - nut; 18 - rotor shaft; 19 - spring washer; 20 * - thrust bushing; 21 - beak-shaped pole pieces of the rotor; 22 - stator core; 23 - bushing; 24 - rotor winding; 25 - rear rotor bearing; 26 - bearing sleeve; 27 - slip rings; 28 - brush holder; 29 - conclusions of the stator winding; 30 - additional diode (valve); 31 - terminal "D" (common output of additional diodes).

Disconnect the battery.
Remove the engine mudguard (see Removing the engine mudguard).
Weaken the belt tension ...

... and remove the tip of the wire from the terminal "+" of the generator.

Using the "10" wrench, unscrew the wire fastening nut ...

... and remove the tip of the wire from the output "+" of the generator.

Remove the plug from the generator plug.

Video (click to play).

Using the "13" wrench, unscrew the nut, holding with the "12" wrench the bolt fastening the generator to the lower bracket.

Using the "13" wrench, unscrew the nut, holding with the "12" wrench the bolt fastening the generator to the upper bracket.

Using the "12" wrench, loosen the bracket bolt.

We take out the bolt with the bushing and remove the generator from the engine.

Using the "10" wrench, unscrew the wire fastening nut.

Using the "8" wrench, unscrew the condenser mounting nut and remove it.

Using the "8" head, unscrew two nuts ...

… And, prying it off with a screwdriver, remove the plastic casing of the generator.

Disconnect the connector from the voltage regulator.

We unscrew the two screws securing the voltage regulator ...

Using the "8" wrench, unscrew the nuts of the bolts tightening the covers.

We unsolder three outputs of the stator winding from the rectifier unit.

Using the "8" wrench, unscrew the three nuts securing the rectifier unit ...

Using the “24” head, using a gas wrench, unscrew the pulley fastening nut, while holding the shaft from turning with a “8” hex key through the holes in the head.

Having pressed the nut flush with the end face of the rotor axis and holding the generator in weight by the fan, we knock out the pulley with not strong blows through a soft drift.

After unscrewing the nut, remove the pulley, fan and thrust bushing.

We mark the relative position of the generator covers and remove the back cover.

We take out the stator from the front cover.

If there is no special puller, screw the nut onto the shaft flush with the butt end and knock the rotor axis out of the front bearing with a soft metal hammer.

Remove the thrust bushing from the axle.

We unscrew the four screws securing the front bearing cover.

We knock out the bearing through the mandrel ...

Using a puller, we dismantle the rear bearing from the rotor shaft.

Press in the new bearing with a suitable sleeve, applying force to the inner ring.

With an ohmmeter, we check that the stator winding is not shorted to the case.

We check the absence of an open circuit in the stator winding.

We check the absence of a short circuit of the rotor winding to the case.

We measure the resistance of the rotor field winding, which should be in the range of 2.3–2.7 ohms.

Applying voltage (12 V) of different polarity to the diodes, we check the serviceability of the rectifier unit.

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