Replacing the brushes and voltage regulator of the generator (Mercedes-Benz Sprinter 903)

It is recommended that you only perform independent adjustment or repair of the generator and the voltage regulator connected to it if you have experience with such work. Some workshops exchange the old generator for a new one and offer installation. The bearings installed in the generator are lubricated for life, so they do not require regular maintenance. The outside of the generator should be kept clean and should not be exposed to water or other liquids.

The generator brushes are in contact with smooth slip rings and are therefore designed for a long service life. To check the brushes, the generator must be removed.

Next, carry out the following work:

• unscrew three bolts 1 (figure 308) and remove cover 2;
• unscrew the brush holder in the block with the voltage regulator 6 from the generator and remove it. To do this, tilt the regulator slightly so as not to damage the brushes;

(Article based on data from the website: www.mercedesman.ru)

• measure the length of the brushes a, as shown in the figure 309. If it is less than 5 mm, unsolder the wires going to the brushes;
• solder new brushes and install the parts in reverse order. Make sure that the brushes are positioned above the contact rings. When installing the voltage regulator, it must come into contact with terminal 4 of the "ground".