Mercedes Benz Alternator Elements Substitute

MERCEDES BENZ ALTERNATORS

Alternators and regulators Bosch with inner regulators
DESCRIPTION
Bosch alternators are standard three-phase, self-rectifying alternators.

75 by 55 amp Bosch alternators use 3 minus 3 plus and diodes linked to stator windings to appropriate present, 90 and 80 amp Bosch alternators use 14 diodes.

All alternators use 3 exciter diodes linked to stator windings, whereas the motor is working these diodes flip off the alternator indicator gentle and provide energy to the voltage regulator.

ALTERNATOR APPLICATION
Mannequin volts/amps

(1) Half no. producer

190E 14/70 489 928
190D 14/70 489 897

All different 14/70 n/a
(1) Bosch alternator half numbers are preceded by the numbers 0 120 or begin with an AL with a quantity and finish with an X.

1. You’ll be able to join a voltmeter to the “B+” terminal of the alternator and floor, the voltmeter ought to learn the battery voltage, if not, test the wiring between the battery and the alternator.

2. Flip the ignition on and test that the alternator indicator gentle comes on. If the sunshine doesn’t come on, test the wiring between the warning gentle and the alternator, together with the test engine gentle.

1. Be certain that the connections on the battery, alternator and starter are clear and tight, make certain the alternator motor and physique are correctly grounded, make certain the alternator belt is tight and in good situation.

2. Join the ammeter in response to the producer’s directions, join the voltmeter results in the battery terminals.

3. Begin the engine and run it at 3000 rpm. Alter the carbon stack to get most output from the alternator, make certain the voltage does not drop under 12.6 volts.

4. The output of the alternator needs to be equal to the rated output of the alternator, minus 16-20 amps, if the studying is 16-20 amps lower than the rated worth of the alternator, change the regulator and retest, if the output continues to be too low, restore or change the alternator.

REGULATOR CHECK VOLTAGE TEST

1. Join the ammeter in response to the producer’s directions, join the voltmeter results in the battery terminals, run the engine at 3000 rpm

2. Run the engine till the voltage stops rising, the voltage needs to be 13.5-14.5 volts. If the studying is wrong, take away the regulator and ensure the brushes are longer than 6mm.

3. If the brushes are OK and the regulator will not be holding the voltage inside the specified limits, change the regulator and retest. If the voltage continues to be incorrect, restore or change the alternator.

REVIEW
DISASSEMBLY

1. Take away the nut, lockwasher and pulley, remembering the place of the spacers. Then take away the fan unit and key, write a mark on the entrance and rear housings, take away the voltage regulator and take away the screws, separate the entrance and rear housings.

2. Disconnect the capacitor from the clamp; take away the nut, insulators, screws and washers.

Take away the stator unit.
3. Unsolder the stator from the diode meeting; take away the corrugated bearing ring or O-ring from the again of the housing.

3. Help the entrance housing and gently push the rotor out, don’t drop the rotor, take away the screws holding the bearing retainer, take away the entrance bearing retainer and seal, take away the rear bearing from the slip ring on the finish of the rotor.

TESTING & REPAIR
Diode mounting
1. Place the size of the ohmmeter on x100 scale, join the leads of the ohmmeter to the “B+” terminal and three stator terminals one after the other, swap the leads, the ohmmeter ought to solely point out continuity in a single route.

2. Reconnect the ohmmeter leads one after the other to the unfavorable and three stator terminals.

reverse leads; ohmmeter ought to point out continuity in a single route solely.

3. Join the ohmmeter leads one after the other to the “D+” terminal and three stator terminals.

Reverse wires, ohmmeter ought to present continuity in a single route solely, if diodes discovered to be defective change diode unit.

Fig. 3: Diode Meeting Take a look at Diode meeting for 55 A alternator is proven, others are comparable.

1. Place the ohmmeter on the bottom scale, join the ohmmeter to the stator leads, the resistance between the leads needs to be 14-15 ohms for a 55 amp alternator and 0.09 10 ohms for 65 to 90 amp alternators. If the resistance is wrong, the stator has open or shorted windings and needs to be changed.

2. Place the ohmmeter on scale X 1000. Join the ohmmeter between the stator core and the stator cable, there needs to be no continuity, if there may be continuity, the stator is grounded and needs to be changed.

1. Place the ohmmeter on the bottom scale, join the ohmmeter throughout the slip rings, the resistance needs to be 3 4-3.75 ohms for a 55 amp alternator and a pair of.8 3.1 ohms for a 65 to 90 amp alternator .

2. If the resistance is just too low, the rotor has a brief circuit and must be changed. If the resistance is infinite, there is no such thing as a continuity. The rotor is open circuit and must be changed.
3. Place the ohmmeter on a scale of x1000, reconnect the ohmmeter between the slip ring and the rotor core. There needs to be no continuity. If there may be continuity, the rotor is grounded and needs to be changed.

4. Clear slip rings with very effective sandpaper, rings which can be worn or pitted needs to be turned on a lathe, minimal ring diameter is 1 1/16″ 26.8mm if slip rings are past restore, change slip rings as described in steps 5 and 6.
5. Take away the rear bearing from the slip ring finish of the rotor, disconnect the wires from the slip rings and bend the ends of the rotor winding up, pull off the slip rings, taking care to not injury the ends of the rotor winding.

6. Insert the ends of the rotor winding into the slip ring and push the brand new slip ring onto the rotor, the slip ring finish needs to be 9/64″ 3.5mm from the top of the collar, solder the rotor winding to the slip ring terminals, tighten the rings the lathe and check rotor once more, most runout slip ring is 0012″.03mm.

The bearings
All the time change the bearings. If the substitute entrance bearing is sealed on just one facet, the open facet ought to face the rotor. If the rear substitute bearing is sealed on just one facet, the open facet ought to face away from the rotor.

Brushes
Ensure that the brushes are longer than 6 mm, change them if essential, unsolder the brushes from the voltage regulator, solder new brushes and ensure that no solder will get into the wires of the comb.

The comb ought to slide freely within the holder with a standard spring stress of 10-14.

REASSEMBLY
1. Set up the bearing, retainer and screws within the entrance housing, press the rotor onto the housing.

Press the slip ring finish of the rotor, solder the stator to the diode meeting, watch out when soldering close to diodes resulting from attainable warmth injury.

2. Set up insulators on the stator meeting, assemble the stator meeting and rear housing, set up a wave washer or O-ring within the rear housing, align the scribe marks, and assemble the entrance and rear housings.

3. Assemble key, fan meeting and spacers, set up pulley, lockwasher and nut, tighten nut to 23-29 ft. 3-4 Nm. Be certain that the rotor rotates freely and set up a voltage regulator and a capacitor.

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