Cars with engine 4062 are equipped with generators 9422.3701 and partially 2502.3771
Generator 9422.3701 is a three-phase synchronous electrical machine with electromagnetic excitation and a built-in rectifier using silicon diodes.
The generator rotor is driven by a poly-V-belt from the engine crankshaft pulley.
The stator and generator covers are secured with four screws. The rotor shaft rotates in bearings installed in the covers.
The bearings are lubricated for their entire service life.
The rear bearing is pressed onto the rotor shaft and into the rear cover.
The front bearing is installed on the inside of the front cover and is secured with a washer and four screws.
The back of the generator is covered with a plastic casing.
The generator stator has two three-phase windings, made in a star configuration and connected in parallel to each other.
The rectifier is a bridge circuit and consists of six power limiting diodes or conventional ones (on some generators). They are pressed into two horseshoe-shaped aluminum holder plates.
One of the plates also contains three additional diodes, through which the excitation winding of the generator is powered after the engine starts.
The generator excitation windings are located on the rotor.
The winding leads are soldered to two copper slip rings on the rotor shaft. Power is supplied to them through two carbon brushes.
The brush holder is structurally combined with the voltage regulator.
The voltage regulator is non-separable; if it fails, it is replaced.
To protect the vehicle’s electronic equipment from voltage pulses in the ignition system, as well as to reduce radio interference, a capacitor is installed between the “+” terminal and the “ground” of the generator.
The internal windings of the generator and the rectifier unit are cooled by centrifugal fans through windows in the covers.
Repair of generator 9422.3701 can be found in the article - "Generator 9422.3701"
Repair of generator 1631.3701 can be found in the article - "Generator 1631.3701"
Generator 2502.3771 has some design differences.
Checking the ZMZ-4062 engine generator on a car
Start the engine, let it run for a few minutes, then increase the crankshaft speed to 3000 rpm –1 .
Turn on the high beam headlights, heated rear window, heater fan, windshield wiper, and hazard lights.
Measure the voltage at the battery terminals, which should be above 13 V.
If this is not the case, then the generator windings are faulty (open or short), the voltage regulator with the brush assembly, or the excitation winding rings are oxidized or oiled.
To make sure that the voltage regulator is working properly, turn off all consumers except the side lights and measure the voltage at a rotation speed of 1000–1200 min –1, which should be in the range of 13.5–14.2 V.
The removed voltage regulator can be checked by connecting a test lamp (21–35 W, 12 V) between the brushes. We connect +12 V to the “D 1” terminal, and “minus” to the “ground” terminal.
The lamp should light up, and when the source voltage increases within 13.5–14.2 V, it should go out.
If the lamp lights up in both cases, the regulator must be replaced.
If its elements fail, it is recommended to replace the rectifier unit as an assembly.
It is also possible to replace individual diodes, but this will require repressing them into the holder. This operation requires accuracy and skill.
Cause of malfunction - Remedy
The generator is running, but the battery is charging poorly or not charging at all
Weak tension of the generator drive belt - Adjust the belt tension
Damage to the voltage regulator - Replace the voltage regulator
The wires on the generator or battery are loose, the battery terminals are oxidized, the electrical wires are broken - Tighten the terminals, clean the battery terminals, replace damaged wires
Wear or sticking of the generator brushes - Replace the brush holder assembly with brushes or restore the mobility of the brushes in the brush holder
Damage to the field winding - Check the soldering of the field winding leads to the slip rings and, if necessary, repair it or replace the field winding
One of the diodes of the rectifier block is broken - Replace the rectifier block
Battery faulty - Replace battery
Increased wear of brushes and slip rings
Increased runout of slip rings - Grind and grind slip rings
Oiling of the slip rings - Eliminate the cause of the oiling and clean the slip rings with gasoline
Change in the elasticity of the brush springs - Replace the brush holder
Recharging the battery
Voltage regulator faulty - Replace voltage regulator
Battery faulty - Replace battery
Increased noise during generator operation
Failure of generator bearings - Replace defective bearings
Rotor touching stator poles - Replace defective bearings
Wear of the bearing seat in the generator cover - Replace the generator cover
