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MERCEDES BENZ ALTERNATORS Alternators & Regulators Bosch with internal regulators Bosch 75 through 55-amp alternators use3 negative 3 positive and diodes connected to stator windings to rectify current, Bosch 90 and 80-amp alternators use 14 diodes. All alternators use 3 exciter diodes connected to stator windings, while the engine is running these diodes turn off the alternator indicator light and supply power to the voltage regulator, Bosch regulators are transistorized solid state and integral with alternator. ALTERNATOR APPLICATION (1) Manufacturer’s Part No. 190E 14/70 489 928 All Others 14/70 N/A 1. You may connect a voltmeter to the alternator “B+” terminal and ground, voltmeter ought to indicate battery voltage, if not check wiring amidst battery and alternator. 2. Turn ignition on and check that alternator indicator light comes on, if light does not come on, check wiring among warning light and alternator, including indicator bulb. 1. Ensure connections at battery, alternator, and starter are clean and tight, make sure alternator engine and body are decently grounded, see to it alternator belt is tight and in good condition. 2. Connect ammeter following manufacturer’s instructions, connect voltmeter leads to battery terminals. 3. Start engine and run at 3000 R.P.M. adjust carbon pile to obtain greatest or most complete or best possible alternator output, do not concede voltage to go underneath 12.6 volts. 4. Alternator output ought to equivalent alternator rated output, minus 16-20 amps, if reading is 16-20 amps under alternator rating, replace regulator and retest, if output is still too low, repair or replace the alternator. REGULATOR CONTROL VOLTAGE TEST 1. Connect ammeter following manufacturer’s instructions, connect voltmeter leads to battery terminals, run engine at 3000 R.P.M. 2. Run engine until voltage stops rising, voltage must be 13.5-14.5 volts, if reading is incorrect, remove regulator and make sure brushes are longer than 6 m.m.. 3. If brushes are okay and regulator fails to keep voltage within specified limits, replace regulator and retest, if voltage is still incorrect, fix or replace alternator. OVERHAUL 1. Remove nut, lock washer, and pulley, do not forget position of spacers, Then remove fan assemblage and key, scribe mark on front and rear housings, remove voltage regulator and remove screws, discerned front and rear housings. 2. Disconnect capacitor from terminal; remove nut, insulators, screws and washers. Remove stator assembly. 3. Support front housing and conservatively press out rotor, do not grant rotor to fall, remove screws securing bearing retainer, remove retainer front bearing and seal remove rear bearing from slip ring at end of rotor. TESTING & REPAIR 2. Reconnect ohmmeter leads all over negative and 3 stator terminals one at a time. Reverse leads; ohmmeter must indicate continuity in one direction only. 3. Connect ohmmeter leads throughout “D+” terminal and 3 stator terminals one at a time. Reverse leads, ohmmeter will have to indicate continuity in one direction only, if diodes are found to be defective, replace the diode assembly. Fig. 3: Diode Assembly Test Diode assemblage for 55 amp alternator is shown, others are similar. 1. Place ohmmeter on lowest scale, connect ohmmeter all over stator leads, resistance amid leads must be 14 15 ohms for 55-amp alternator and .09 10 ohms for 65 through 90 amp alternators, if resistance is incorrect, stator has open or shorted windings and will have to be replaced. 2. Place ohmmeter on X 1000 scale. Connect ohmmeter amidst stator core and stator lead, no continuity will have to exist, if continuity exists, stator is grounded and will have to be replaced. 1. Place ohmmeter on lowest scale, connect ohmmeter all over slip rings, resistance ought to be 3 4-3.75 ohms for 55 amp alternator and 2.8 3.1 ohms for 65 through 90 amp alternators. 2. If resistance is too low, rotor has short circuit and it must be substituted if resistance is infinity no continuity, rotor has open circuit and will have to be replaced. 4. Clean slip rings using a very fine sandpaper, rings which are worn or pitted ought to be turned on lathe, minimum ring diameter is 1 1/16″ 26.8 m.m. if slip rings are beyond repair, replace slip rings as outlined in steps 5 and 6. 6. Insert the ends of rotor winding into slip ring and press new slip ring onto rotor, slip ring end will have to be 9/64″ 3.5 m.m. from end of the collar, solder rotor winding to slip ring terminals, turn rings on lathe and retest rotor, greatest or most complete or best possible slip ring run out is 0012″.03 m.m.. The Bearings Brushes Brush will have to be free to slide in holder with normal spring tension of 10-14. REASSEMBLY Press bearing on slip ring end of the rotor, solder stator to diode assembly, exercise care when soldering near diodes due to possible heat damage. 2. Install insulators on stator assembly, assemble stator assemblage and rear housing, install wave washer or O ring in rear housing, align the scribe marks and assemble front and rear housings. 3. Install key, fan assembly, and spacers, install the pulley, lock washer and nut, tighten nut to 23-29 ft. 3-4 Nm. Ensure rotor spins freely, and install voltage regulator and capacitor. |
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