Charging System - Insufficient Charging
Date: November 1, 2004Order No.: P-B-15.40/54
Supersedes:
Group: 15
SUBJECT:
All Model 203, 209, 211, 215, 220 and 230 with M112/113 Engine All Model Years
Alternator/Generator Voltage Regulator Malfunction
On the above model vehicles, if you encounter insufficient alternator/generator (G2) output, the voltage regulator, integral to G2 may be malfunctioning. The voltage regulator may be replaced as a separate part and the procedure below should be followed.
1. Check regulation voltage of generator (G2) as per WIS instructions:
- Model 203/209: AR15.40-P-5010P
- Model 211: AR15.40-P-5010I
- Model 215/220: AR15.40-P-5010I
- Model 230: AR15.40-P-5010R
2. If the generator fails the above test procedure, then remove the unit from the vehicle for repair on a work bench. Refer to WIS Group 15.40 for the correct instructions, depending on the model and body variant.
3. Remove the plastic cover from the rear of the generator, by first removing the two nuts from the studs (Figure 1, 1) and the one Phillips head screw (Figure 1, 2). Note which nut is removed from either stud.
4. Remove the voltage regulator (Figure 2, 1) from the generator, by removing the three Phillips head screws (Figure 2, 2 and 3).
5. Check the following prerequisites to ensure that only the regulator needs to be exchanged. If any of the below items fail, then the entire generator needs to be replaced and you may proceed to step 8.
a) There are no scorch marks or damage on the slip ring of the generator rotor (Figure 3, 1)
b) Carbon brush length of defective regulator at least 5 mm (Figure 4, 1)
c) Wear on the two brushes of the defective regulator is even (maximum 1 mm difference).
6. Install new voltage regulator and tighten Phillips head screws to:
a. (Figure 2, 2) = 2.0-2.4 Nm
b. (Figure 2, 3) = 1.0-1.4 Nm.
7. Install the plastic cover on the back of the generator and tighten the Phillips head screw (Figure 1, 2) to 2.2-2.6 Nm and the two nuts (Figure 1, 1) as follows:
a. Long stud 29.0-32.0 Nm
b. Short stud to 11.0-13.0 Nm.
8. Reinstall the repaired generator or the new generator in reverse order and verify proper operation as described in step 1.
Note:
Due to the several versions of alternator/generators used in production on all the above models, please refer to EPC for the correct voltage regulator part number application. The correct part numbers may be found in group 15 and/or group 54 in EPC.
Note:
The following allowable labor operations should be used when submitting a warranty claim for this repair.
In Case of Warranty, use the table.