Mercedes Benz Alternator Components Substitute

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MERCEDES BENZ ALTERNATORS

Alternators & Regulators Bosch with inside regulators

DESCRIPTION

Alternators made by Bosch are standard 3-phase, self-rectifying kind alternators.

Bosch 75 by way of 55-amp alternators use3 destructive 3 optimistic and diodes linked to stator windings to rectify present, Bosch 90 and 80-amp alternators use 14 diodes.

All alternators use 3 exciter diodes linked to stator windings, whereas the engine is operating these diodes flip off the alternator indicator mild and provide energy to the voltage regulator, Bosch regulators are transistorized stable state and integral with alternator.

ALTERNATOR APPLICATION

Mannequin Volts/Amps

(1) Producer’s Half No.

190E 14/70 489 928

190D 14/70 489 897

All Others 14/70 N/A

(1) Bosch alternator half numbers are preceded by the numbers 0 120 or starting with an AL lettering a quantity and ending with an X.

1. You may join a voltmeter to the alternator “B+” terminal and floor, voltmeter ought to point out battery voltage, if not verify wiring between battery and alternator.

2. Flip ignition on and verify that alternator indicator mild comes on, if mild doesn’t come on, verify wiring between warning mild and alternator, together with indicator bulb.

1. Guarantee connections at battery, alternator, and starter are clear and tight, guarantee alternator engine and physique are correctly grounded, guarantee alternator belt is tight and in good situation.

2. Join ammeter following producer’s directions, join voltmeter results in battery terminals.

3. Begin engine and run at 3000 R.P.M. modify carbon pile to acquire most alternator output, don’t permit voltage to go under 12.6 volts.

4. Alternator output ought to equal alternator rated output, minus 16-20 amps, if studying is 16-20 amps under alternator ranking, exchange regulator and retest, if output continues to be too low, restore or exchange the alternator.

REGULATOR CONTROL VOLTAGE TEST

1. Join ammeter following producer’s directions, join voltmeter results in battery terminals, run engine at 3000 R.P.M.

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

3. If brushes are okay and regulator fails to maintain voltage inside specified limits, exchange regulator and retest, if voltage continues to be incorrect, restore or exchange alternator.

OVERHAUL

DISASSEMBLY

1. Take away nut, lock washer, and pulley, keep in mind place of spacers, Then take away fan meeting and key, scribe mark on entrance and rear housings, take away voltage regulator and take away screws, separate entrance and rear housings.

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

Take away stator meeting.

3. Unsolder stator from diode meeting; take away bearing wave washer or o ring from rear of housing.

3. Help entrance housing and punctiliously press out rotor, don’t permit rotor to fall, take away screws securing bearing retainer, take away retainer entrance bearing and seal take away rear bearing from slip ring at finish of rotor.

TESTING & REPAIR

Diode Meeting

1. Place ohmmeter scale on x100 scale join ohmmeter leads throughout “B+” terminal and three stator terminals separately, reverse leads, ohmmeter ought to point out continuity in a single path solely.

2. Reconnect ohmmeter leads throughout destructive and three stator terminals separately.

Reverse leads; ohmmeter ought to point out continuity in a single path solely.

3. Join ohmmeter leads throughout “D+” terminal and three stator terminals separately.

Reverse leads, ohmmeter ought to point out continuity in a single path solely, if diodes are discovered to be faulty, exchange the diode meeting.

Fig. 3: Diode Meeting Check Diode meeting for 55 amp alternator is proven, others are comparable.

1. Place ohmmeter on lowest scale, join ohmmeter throughout stator leads, resistance between leads needs to be 14 15 ohms for 55-amp alternator and .09 10 ohms for 65 by way of 90 amp alternators, if resistance is wrong, stator has open or shorted windings and should be changed.

2. Place ohmmeter on X 1000 scale. Join ohmmeter between stator core and stator lead, no continuity ought to exist, if continuity exists, stator is grounded and should be changed.

1. Place ohmmeter on lowest scale, join ohmmeter throughout slip rings, resistance needs to be 3 4-3.75 ohms for 55 amp alternator and a couple of.8 3.1 ohms for 65 by way of 90 amp alternators.

2. If resistance is simply too low, rotor has quick circuit and it should be changed if resistance is infinity no continuity, rotor has open circuit and should be changed.

3. Place ohmmeter on x1000 scale, reconnect ohmmeter between both the slip ring and rotor core, no continuity ought to exist, if continuity exists, rotor is grounded and should be changed.

4. Clear slip rings utilizing a really high quality sandpaper, rings that are worn or pitted needs to be turned on lathe, minimal ring diameter is 1 1/16″ 26.8 m.m. if slip rings are past restore, exchange slip rings as outlined in steps 5 and 6.

5. Take away rear bearing from slip ring finish of rotor, unsolder wires from slip rings and bend up ends of rotor winding, pull off slip rings, guarantee ends of rotor winding are usually not broken.

6. Insert the ends of rotor winding into slip ring and press new slip ring onto rotor, slip ring finish should be 9/64″ 3.5 m.m. from finish of the collar, solder rotor winding to slide ring terminals, flip rings on lathe and retest rotor, most slip ring run out is 0012″.03 m.m..

The Bearings

All the time exchange bearings, if substitute entrance bearing is sealed on one aspect solely, open aspect should face rotor, if substitute rear bearing is sealed on one aspect solely, open aspect should face away from rotor.

Brushes

Guarantee brushes are longer than 6 m.m. exchange if vital, unsolder brushes from voltage regulator, solder new brushes, and don’t permit solder to run into strands of brush leads.

Brush should be free to slip in holder with regular spring stress of 10-14.

REASSEMBLY

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

Press bearing on slip ring finish of the rotor, solder stator to diode meeting, train care when soldering close to diodes resulting from potential warmth harm.

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

3. Set up key, fan meeting, and spacers, set up the pulley, lock washer and nut, tighten nut to 23-29 ft. 3-4 Nm. Guarantee rotor spins freely, and set up voltage regulator and capacitor.

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Source by Clint Hough