Alternator: Testing and Inspection

Up To may 31 1999







Testing


DANGER: Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury from caustic burns to eyes and skin from battery electrolyte or from handling damaged lead acid batteries
- No fire, sparks, naked flames or smoking. Wear acid-protective gloves, clothing and eye protection. Pour battery electrolyte only into suitable and appropriately marked containers.


CAUTION: Notes on battery
- All models


1 Measure acid density
Refer to Commercially Available Tools below
- Acid density below minimum value:
- Charge battery.
- Refer to Test And adjustment Values For Battery, Voltage Supply below

2 Prerequisites for testing
3 Connect multimeter (003) according to connection diagram


DANGER: Risk of accident from vehicle starting off by itself when engine running. Risk of injury from bruises and burns if you hold your hand into engine when it is started or when it is running.

- Secure vehicle to prevent it moving off by itself.
- Wear closed and close-fitting work clothes.
- Do not grasp hot or rotating parts.


4 Start engine
5 Check function of charge indicator lamp when engine is idling and with increasing engine speed (up to 3000 rpm)
- Charge indicator lamp must extinguish.

6 Check regulating voltage


NOTE: Only connect battery to permanent consumer (e.g. Ignition).


- Engines 104, 111,112,113,119.
- Engines 602, 604, 605, 606, 611, 612, 613.
- Regulating voltage > 14.5 V:


1. Replace regulator:
NOTE: With engine 611 as of 1.6.99, engines 612 and 613 not possible.


2. Replace generator (if regulator is OK):
- Engines 112, 113, 119.
- Engines 104, 111, 602, 604, 605, 606, 611 up to 31.5.99.
- Engines 611 as of 1.6.99, 612, 613.

- Regulating voltage < 13.0 V:
1. Eliminate transition impedance from charging system at electric connections.
2. Check diodes of generator.
3. Replace generator (if diodes are defective):
- Engines 112, 113, 119.
- Engines 104, 111, 602, 604, 605, 606, 611 upto 31.5.99.
- Engines 611 as of 1.6.99, 612, 613.

7 Switch off engine
8 Disconnect multimeter (003)

Test And Adjustment Values For Battery, Voltage Supply:

Test Values Of Regulator:

Commercially Available Tools: