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  #1  
Old 20-06-10, 07:51
antonio antonio is offline
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Join Date: Jun 2010
Location: Edmonton (AB) Can
Posts: 6
Default Iltis Alternator Problems

Hey guys, I have 4 Iltis jeeps, 2 for parts and 2 that runs. Well at least they ran long enough to get off the transporting trailer....

One of them has an over voltage production that i can get to lower. I've bought a new alternator (at a great expense) but even the new one over charges the batteries at 32+ volts (I've shut down the engine at 32 volts) The batteries are fully charged with a battery charger so the alternator shouldn't have to work so hard. I have the service manual in which it just says to "turn the adjusting screw counter-clock wise to reduce the voltage" but all that does is buying me a few more seconds before the voltage reaches 32v. I've cleaned up the battery terminal and even redid some of cable ends, but still no change.

And i'm out of ideas. Reading through this forum i saw a lot of people here with extensive knowledge on Iltis so maybe someone has seen this type of problem before.

The other one has a constant idling voltage of 24 volt (23.5 when fully loaded) so I'll try one of those "full-fielded output voltage test" tomorrow...

Thanks for any help
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  #2  
Old 20-06-10, 08:53
matthewq4b matthewq4b is offline
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Location: St Albert
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I Had a similar issue the alt would occasionally over charge. I also had a faulty head lamp light switch it worked but would drop out on over load when the headlights were turned on. The Alt Over load had no corelation at all to whether the head lights were on or off. When I changed the switch the Alt over charge issue vanished.


Matthew
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  #3  
Old 20-06-10, 09:54
rob love rob love is offline
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Join Date: Feb 2003
Location: Shilo MB, the armpit of Canada
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90% of the over voltage problems that I experienced on the Iltis were due to poor connections. Loose terminals at the batteries would cause the alternator to over compensate and in the end would boil the batteries and fry the alternator. Make sure the cables are clean and tight at the batteries. Another potential problem area is the main connection at the starter. It acts as a junction for a number of wires. If this is loose, it also results in an over voltage problem. You can also check the connections at the master switch. Also, a bad battery (or two) can cause the over voltage problem. Check the batteries cell condition with a hydrometer; all cells should be equal within 20 points of each other. A single bad cell can cause the problems you are describing. Hydrometers are available at Cdn tire for under $10. If a cell is bad, the battery must be replaced, and on a 24 volt system, both batteries should be of relatively equal condition.

As an aside, there was a small bridge on the replacement alternators that also cause a bit of a problem. It was found that the vehicles could be started without the master switch if this bridge was allowed to remain. The bridge ran from the positive stud on the alternator over to the field (IIRC).
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  #4  
Old 20-06-10, 17:21
Yeo.NT's Avatar
Yeo.NT Yeo.NT is offline
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Location: Carberry Manitoba
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The alternator is not your problem, If i can produce voltage 32v it because the regulator is telling it to produce that much. Your regulator is the problem, try a different regulator and set it to charge at 27-28v
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  #5  
Old 20-06-10, 17:47
rob love rob love is offline
carrier mech
 
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Quote:
Originally Posted by Yeo.NT View Post
The alternator is not your problem, If i can produce voltage 32v it because the regulator is telling it to produce that much. Your regulator is the problem, try a different regulator and set it to charge at 27-28v
Agreed that if it's charging, just the regulator portion can be changed, but if two different alternators are doing the same thing, and the adjustment won't work, then one should be looking for an external problem. Mind you, it would not be the first time someone installed a red herring (a bad alternator to replace a bad alternator).
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  #6  
Old 20-06-10, 21:25
Rpoolie Rpoolie is offline
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Location: Aurora, Ontario
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I just went through the same troubles (sporadic overcharging).
After checking all the grounds, finally removed the alternator and regulator and asked a local alt/gen repair shop to test.
Bottom line, after testing the reg was found to be faulty and was replaced, with no troubles since.
Cost was $140.00 taxes in.
The best advice to offer you is to send the unit to a repair shop for testing.
Would have saved me some time and frustration!
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  #7  
Old 07-03-21, 01:41
BCA BCA is offline
Brian Asbury
 
Join Date: Oct 2006
Location: Ontario, Canada
Posts: 638
Default Intermittent overcharging

I’m trying to solve an intermittent overcharging in my Iltis. Two questions: the pivot bracket is hard to access. I see a nut at the rear end, but do you have to remove the front guard plate to access another bolt at the front end of the alternator bracket? Secondly, having removed the voltage regulator from the alternator, is there a trick to compressing the “Jack-in-the-Box” brush springs in order to replace the regulator?
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  #8  
Old 07-03-21, 11:34
super dave super dave is offline
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Location: Onoway, Alberta, Canada
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In the front timing cover there is a access hole and it you use a 6mm Allen key as its a cap head bolt. as for the brushes there is a small hole in the back of the brush holder so you would install the brushes and the springs then push them down and then you would insert a small piece of wire across both of them to a small hole on the other side to hold the brushes down until you install the regulator than remove the wire once you feel the regulator sitting on top of the wire, See pics. Hope this helps.
Attached Images
File Type: jpg 20210307_025224 33.jpg (294.9 KB, 1 views)
File Type: jpg 20210307_031948 35.jpg (448.3 KB, 1 views)
File Type: jpg 20210307_031902 34.jpg (278.0 KB, 1 views)
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  #9  
Old 07-03-21, 15:03
BCA BCA is offline
Brian Asbury
 
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Location: Ontario, Canada
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Thank you Dave, now clear as a bell. I did check the Iltis maintenance manual and couldn’t find anything that deals with these issues. .... Brian
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  #10  
Old 04-07-21, 15:20
Stuart Fedak Stuart Fedak is offline
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Join Date: Jan 2006
Location: Canada
Posts: 249
Default Iltis Maintenance Manual page 2-5-30

Ref: Iltis Maintenance Manual page 2-5-30

Manual:

25. Installation — To install, proceed as follows:

a. Insert the outer brush and spring
assembly into the housing and compress
the brush spring with a small
screwdriver. While holding the spring
compressed, insert a stiff piece of wire
through the top hole in the rear of the
housing so that the spring will be held
in the compressed position.

b. Install and compress the second brush
and spring and push the wire further
into the brush housing to hold the second
brush in the compressed position
also.

c. Carefully push the regulator into the
brush housing until the regulator contacts
the brushes. Ensure a screw goes
through the negative jumper.

d. Install the lock washers and nuts and
hand tighten.

e. Remove the wire that compresses the
springs and torque the nuts to 125
N•cm (11 in lb).
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  #11  
Old 04-07-21, 15:37
Stuart Fedak Stuart Fedak is offline
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Join Date: Jan 2006
Location: Canada
Posts: 249
Default Iltis Alternator removal maintenance manual

Maintenance Manual page 2-5-12 & 2-5-13

Note: often the "plastic plug cover" is missing.

ALTERNATOR
18. General — The alternator mounting bushings
and bolt should be periodically inspected and
tightened, or replaced when necessary, to prevent
vibration damage to the alternator (refer to Section
6).
19. Removal — To remove, proceed as follows:
a. Disconnect the battery ground cable.
b. Disconnect wire #1 from the alternator
regulator with a 3/8 in. wrench.
c. Disconnect wire #1D from the alternator
regulator with a 1/4 in. wrench.
d. Disconnect both positive wires #2 from
the alternator with a 1/2 in. wrench.
e. Disconnect negative wire #52 from
the alternator with a 1/2 in. wrench.
f. Remove the bolt, lock washer and flat
washer from the adjusting arm and remove
the drive belts.
g. Swing the adjusting arm out of the
way.
h. Remove the plastic plug from the upper
timing belt cover, see Figure 2-5-5,
and insert a 6 mm hex head socket
through the opening and onto the head
of the alternator mounting bolt.

j. Remove the nut from the mounting bolt.
k. Support the alternator and withdraw
the mounting bolt until it is free of the
alternator.
m. Remove the alternator from the mounting
bracket.
Attached Images
File Type: jpg Alternator-bolt-plastic-plug-001.jpg (305.7 KB, 0 views)
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