Is there a wrong way to install a voltage regulator?

[doug]

Well, okay, obviously you could insert it in the air cleaner or the washer tank and that would be wrong. What I mean is, install it in the proper location but only almost in the right location, not quite there. The reason I ask is because I replaced mine about 3 months ago, and just started noticing the battery light coming on. I messed with all the grounds for awhile, then decided to pull the regulator. What I found is that one of the brushes was mostly worn down about 3 mm (which seems like a lot after only three months) but there was a real narrow strip that hadn't been worn at all. I broke that piece off, filed it down smooth, put the regulator back in, and now it seems to be charging okay. So why did that brush wear funny like that?

[tacm]

on the rotor of the alternator there is a contact that the brush rides on its called a slip ring and it is worn there is no good way for a DIY to fix this so your best bet is to replace your alt. with a rebuilt as soon as you can.........Steve

edit.......by the way for those of you who dont know a lot about auto chargings systems the reason that Bosh puts the brusses on the regulator it that a voltage regulator does not regulate direct voltage output it regulates input field voltage to the rotor that determines how much the altenator will put out.....hope i was of some help

[Edit by tacm on [TIME]1109766762[/TIME]]

[Shawn D.]

[QUOTE="dotrp"]... one of the brushes was mostly worn down about 3 mm (which seems like a lot after only three months) but there was a real narrow strip that hadn't been worn at all. I broke that piece off, filed it down smooth, put the regulator back in, and now it seems to be charging okay. So why did that brush wear funny like that?[/QUOTE]
The brushes and the rings can be equated to brake pads and rotors. Your brake pads and rotors can develop mating grooves, right? Then, if you put new pads onto the grooved rotors, what happens to the pads? Yep, they become grooved. I'd bet that's what happened here. Use a mirror and flashlight to check out the rings and you'll see what I'm talking about.

[doug]

I neglected to mention that the unworn piece of the brush was on the very edge of the brush ... maybe less than .5 mm thick. It seemed as though the regulator needed to be moved over just a tad, but of course there's no way to know that when you're installing it ... or is there? I'll have a look at the rotor, but I don't think that's the problem since the brushes on the previous regulator showed no abnormal wear.

[dworthy]

It could just be the replacement regulator/brushes wasn't built to proper spec. If you had a lip, that is just miss-alignment of the brushes itself when manufactured. Normal the voltage regulator/brushes should last at least 5 years, but I have seen them last as long a 10. Of course it all comes down to driving, how much and how often, different engines rev, etc..

I would guess that you just bought a off the self and not a Bosch replacement.

[doug]

[QUOTE="dworthy"]I would guess that you just bought a off the self and not a Bosch replacement.[/QUOTE]

I got the parts from Steve. I don't believe it said Bosch on the box ... I could be wrong.

[dworthy]

I maintained the local generator for my company while in Iraq, it ran the showers and kept the water warm. One of the brushes was miss-aligned and it cause the same thing as your regulator, and the ring had a couple of grooves in it, but no real big deal.

[RetiredDoc]

Here's a site with illustrated basics about alternators, voltage regulators, brushes, slip rings and such. ~0

http://www.bcae1.com/charging.htm