Disassembling/assembling the alternator

AR15.30-I-7300A

Disassembling/assembling the alternator

15.1.10



Removing

1

Remove starter

AR15.30-I-7100A



Disassemble

2

Unscrew bolts (16) and remove cover (17), spacer (10), shims (20, 21) and seal (18)

3

Remove stator winding connection (31) on magnetic switching relay (4)

4

Remove bolts (3) and Magnetic switching relay (4) from drive bearing case (2)

 The anchor on the magnetic switching relay (4) is removed from the lever (10) for this procedure.

5

Remove bolts (22), spacer (23) and bearing cap (24) from dynamo body (30) and carbon brush holder (26)

6

Bend out retaining bracket on carbon brush holder (26) then remove springs (27) and carbon brushes (28)

7

Remove carbon brush holder (26) from rotor (14)

8

Remove dynamo body (30) together with the rotor (14)

9

Remove through bolts (15)

10

Remove bolt (9) and nut (12), spring washer (11) and rotor (14) together with the lever (10) from drive bearing (2)

11

Remove stop ring (6) using a suitable tool

12

Remove circlip (5)

 Remove the burr on the groove carefully in order to avoid damaging the drive bearing bush.

13

Press latch with the brake disk against the drive (8) and detach the rotor shaft together with the intermediate bearing (13)

14

Unscrew bolts (29) and remove stator winding (32) from dynamo body (30)

15

Clean parts

 Do not wash out electrical parts.

 Wash out parts using non-combustible, commercially available cleaners.

Blow out parts with compressed air (maximum of 4 bar). Lubricate metal parts. Allow the parts to dry out fully in order to avoid a gas build up in the sealed starter.



Checking

16

Check starter components

AR15.30-I-7300-01A

Smooth operation of rotor on laminated core

*BE15.30-N-1001-01A

Smooth operation of rotor on slip ring

*BE15.30-N-1002-01A

Minimum length of carbon brushes

*BE15.30-N-1008-01A



Assembling

17

Press intermediate bearing (13) and drive (8) together with the lock rings and the brake disk on the rotor shaft (14)

 Grease drive and spiral toothing.

The lock rings must sit exactly in the rotor shaft after installation.

The drive must freely move on the shaft after closing.

18

Press stop ring onto rotor shaft, slightly widen the circlip (5) and insert in the radial groove

 Do not damage rotor shaft or clamp the rotor.

19

Press suitable sleeve onto the rotor shaft, hold the drive pinion using pliers, turn and press against the stop ring

20

Use a plastic mallet to lightly hammer against the sleeve until the circlip (5) moves to its position under the stop ring (6)

21

Insert stator winding (32) into the dynamo body (30) and fix in place with bolts (29)

22

Lubricate lever (10) and insert together with the rotor (14) into the drive bearing housing (2)

23

Fix lever (10) in place with bolt (9), spring washer (11) and nut (12)

24

Insert through bolts (15) into the drive bearing housing (2) and tighten

25

Mount dynamo body (30) and drive bearing housing (2) together with the rotor (14)

 The through bolts (15) must not touch the stator winding (32).

26

Mount carbon brush holder (26) on rotor shaft

27

Push carbon brushes (28) and springs (27) downwards and push in retaining bracket



- Replace damaged or corroded springs.

- The connecting wires for the carbon brushes (28) are welded on in the original condition. New carbon brushes are screwed on. Used carbon brushes (28) are pinched off or screwed off. When mounting new carbon brushes (28) ensure that the cable lug is mounted in the correct position (arrow).

28

Check carbon brush holder (26) for a short circuit

Test short circuit voltage for carbon brush holder (AC)

*BE15.30-N-1005-01A

29

Mount bearing cap (24) and spacer washers (23) and lighten down with nuts (23)

 Check whether the insulating sleeves on the connecting cable of the stator winding are seated correctly.

30

Install tolerance washers (20, 21) with the inserted positioning washer (19) and check rotor play in the longitudinal direction and adjust tolerance washers (20, 21) if necessary

Rotor play in longitudinal direction.

*BE15.30-N-1003-01A

31

Lubricate cover (17) inside, mount seal (18) and tighten down using bolts (16)



 Replace gasket.

*BR00.45-Z-1001-06A

32

Check clearance between stop ring (6) and drive (8)

 Dimension 'A': 16.5-19.5 mm

AR15.30-I-7300-01A

33

Check magnetic switching relay (4) for conductance and short circuit to ground

Test through voltage for magnetic switching relay (AC)

*BE15.30-N-1006-01A

34

Lubricate moving parts on magnetic switching relay (4) and install on lever (10)



*BR00.45-Z-1001-06A

35

Install magnetic switching relay (4) using bolts (3)

36

Screw stator winding connection (31) onto magnetic switching relay (4)



Removing

37

Install starter

AR15.30-I-7100A

Number

Designation

Engine 384.906/
907

BE15.30-N-1001-01A

Smooth operation of rotor on laminated core

mm

0.05

BE15.30-N-1002-01A

Smooth operation of rotor on slip ring

mm

0.03

BE15.30-N-1003-01A

Rotor play in longitudinal direction.

mm

0.1 to 0.3

BE15.30-N-1004-01A

Test short circuit voltage on rotor

V

80

BE15.30-N-1005-01A

Test short circuit voltage for carbon brush holder (AC)

V

80

BE15.30-N-1006-01A

Test through voltage for magnetic switching relay (AC)

V

6

BE15.30-N-1008-01A

Minimum length of carbon brushes

mm

15.5

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11