Remove/install regulator for alternator

AR15.40-D-5760R

Remove/install regulator for alternator

13.09.2013

ENGINE

646 in MODEL 909

1

Support brace

2

Nut

3

Electrical connection

4

Electrical line, circuit 30 (B+)

G1

Alternator

Alternator manufacturer Valeo

6

Cap

7

Screw/bolts

8

Controller

9

Cap

10

Slip rings

G1

Alternator

Alternator manufacturer Bosch

11

Cap

12

Screw/bolt

13

Collar nut

14

Nut

15

Screw/bolt

16

Screw/bolt

17

Controller

18

Slip rings

G1

Alternator

 Danger !

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 Danger !

Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries

No fires, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

 

Remove/install

1

Disconnect battery ground line



Notes on battery

AH54.10-P-0001-01A

2

Lift/jack up vehicle

AR00.60-D-1000F

3

Remove support brace (1) for turbocharger

 Screw/bolt, turbocharger support brace to cylinder crankcase

*BA09.40-N-1005-01O

 Screw/bolt, support brace to turbocharger

*BA09.40-N-1007-01O

4

Disconnect electrical connection (3)

5

Detach protective cap from nut (2)

6

Disconnect electrical line of circuit 30 (B+) (4) at the alternator (G1)

 Nut, circuit B+ to alternator

*BA15.40-N-1002-01P

7.1

Unclip and remove cap (6) on alternator (G1)

Alternator manufacturer Valeo

 Installation: Check the cast in latches (arrows) on the cap (6) for damage; replace the cap (6) if necessary.

 Unclip cap (6) on the three cast in latches (arrows).

7.2

Remove screw/bolt (12); unscrew collar nut (13) and nut (14)

Alternator manufacturer Bosch

 Bolt, connecting cover to alternator

*BA15.40-N-1020-01P

 Collar nut, cover to alternator

*BA15.40-N-1019-01P

 Nut, cover to alternator

*BA15.40-N-1018-01P

8

Remove cap(11) from alternator (G1)

Alternator manufacturer Bosch

9.1

Remove screws/bolts (7) and remove control (8)

Alternator manufacturer Valeo

 Installation: Replace control (8). For a new control (8) the cap (9) is preassembled in the assembly position, the carbon brushes are held back in this way. Push the cap (9) into its end position after tightening down the control (8). The carbon brushes are released and come to the stop on the slip rings (10).

 Bolt, regulator to alternator

*BA15.40-N-1021-01P

9.2

Remove screws/bolts (15, 16) and remove control (17)

Alternator manufacturer Bosch

 Installation: Replace control (17).

 Bolt, regulator to alternator

*BA15.40-N-1021-01P



Check

10

Check slip rings (10, 18) in alternator (G1) for galling or damage

For galling or damage replace alternator (G1):



Remove/install alternator

AR15.40-D-5032R

11

Install in the reverse order

 Turbocharger

Number

Designation

ENGINE 646.7 in MODEL 909

BA09.40-N-1005-01O

Screw/bolt, turbocharger support brace to cylinder crankcase

Nm

20

 Turbocharger

Number

Designation

ENGINE 646.7 in MODEL 909

BA09.40-N-1007-01O

Screw/bolt, support brace to turbocharger

Nm

30

 Alternator

Number

Designation

ENGINE 646.7 in MODEL 909

BA15.40-N-1002-01P

Nut, circuit B+ to alternator

Nm

16

 Alternator

Number

Designation

ENGINE 646.7 in MODEL 909

BA15.40-N-1018-01P

Nut, cover to alternator

Nm

12

 Alternator

Number

Designation

ENGINE 646.7 in MODEL 909

BA15.40-N-1019-01P

Collar nut, cover to alternator

30

 Alternator

Number

Designation

ENGINE 646.7 in MODEL 909

BA15.40-N-1020-01P

Bolt, connecting cover to alternator

Nm

3

 Alternator

Number

Designation

ENGINE 646.7 in MODEL 909

BA15.40-N-1021-01P

Bolt, regulator to alternator

Nm

3