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Repair and Testing Instructions for T1
Page 1
Alternator 0120 689 552
Edition 001
Repair and Testing
Instructions for
T1 Alternator
0120 689 552
All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp.
UA/ASV
04.12.98
T1ALTFinal.DOC
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Table of Contents
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Summary of Contents for Bosch T1 Alternator
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Page 1: Alternator 0120 689 552 Edition 001
Alternator 0120 689 552 Edition 001 Repair and Testing Instructions for T1 Alternator 0120 689 552 All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98 T1ALTFinal.DOC... - Page 2 Edition Date Name Modifications 8/28/98 I. Serra Original 12/4/98 I. Serra Update 8.98 Instructions All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98 T1ALTFinal.DOC...
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Page 3: Table Of Contents
ALTERNATOR ASSEMBLY..........................27 10.1 ............................. 27 OTOR SSEMBLY 10.2 ........................... 28 RIVE HIELD SSEMBLY All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98 T1ALTFinal.DOC... - Page 4 Shorted Positive Rectifier Diode ....................... 43 11.3.8 Shorted Negative Rectifier Diode......................44 11.3.9 Open Phase of Stator ..........................45 All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98 T1ALTFinal.DOC...
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Page 5: General
T1 (RL) 28V 70/140A Note: Alternator 0 120 689 543 was utilized in preparing these instructions. All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 6: Safety Precautions
Avoid exposure to fire, open flame and sparks. Thoroughly dry all cleaned parts as gases could form from the cleaning process and may cause an explosion. All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 7: Specifications
10x divisions. Figure 1 Normal Oscilloscope Pattern All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 8: Mechanical Test Specifications
Pulley Retaining Nut 135 … 170 99.5 … 125.4 ft. lbs. Figure 2 Fastener Torque Chart All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98 T1ALTFinal.DOC... -
Page 9: Alternator Schematic
Dynamo + (Warning Lamp Output) Tachometer Output Voltage Regulator Dynamo + (Alternator Output) Dynamo Field Dynamo - All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98 T1ALTFinal.DOC... -
Page 10: Alternator Coding
120 … 129 mm 130 … 139 mm 170 … 199 mm more than 200 mm All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98 T1ALTFinal.DOC... -
Page 11: Parts Cleaning
Avoid exposure to fire, open flame and sparks. Thoroughly dry all cleaned parts as gases could form from the cleaning process and may cause an explosion. All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 12: Tools, Test Equipment Lubricants And Adhesives
EFAW 7 1 687 233 011 Magnetic Indicator Stand T-M 1 4 851 601 124 All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98 T1ALTFinal.DOC... -
Page 13: Lubricants And Adhesives
Collector End Shield Radial Seal 2 g (0.07 oz.) Roller Bearing 2…2.5 g (0.07…0.09 oz.) All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98 T1ALTFinal.DOC... -
Page 14: Exploded View
17/3/801 Carbon-Brush Set Protective Cap 17/10 Gasket Air-Intake Cover Stator Grommet Spring Lock Washer All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98 T1ALTFinal.DOC... -
Page 15: Alternator Disassembly And Testing
Note: The brushes of the regulator will break if the regulator is not removed before any other disassembly of the alternator takes place. All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 16: Brush Replacement
9.3 Noise Suppression Capacitor Testing and Removal 1. Disconnect the suppression capacitor from terminal B+. All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 17: Pulley And Fan Removal
1. Loosen and remove the four (4) outer Oval-head screws which hold the end shields together. (Figure 10) All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. -
Page 18: Rectifier Assembly Testing
Figure 11 Testing of Rectifier Assembly All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 19: Removal And Testing Of Stator Assembly
Use insulated gloves and do not touch the work surface until all tests are completed. All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 20: Rectifier Assembly Removal
Terminal W is attached to the collector end shield. Do not loosen Terminal W. 4. Remove the rectifier assembly from the collector end shield. All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 21: Dampening Resistor Testing And Removal
4. Screw on the handle, rotate until the bearing, and seal come out of the collector end shield. (Figure 16) Figure 16 Bearing and Seal Removal All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 22: Removal Of Sliding Bushing In Collector End Shield
1. Place drive end shield onto pressing ring KDLJ 6013 (Bosch Number 0 986 618 127). 2. Place pressing ring into an arbor press. (Figure 18) All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... - Page 23 • the rotor collector rings are to be replaced All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98...
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Page 24: Removal Of Bearing And Seal From Drive End Shield
2. Reposition the puller and remove the spacer ring from the rotor shaft. Figure 20 Inner Bearing Race Removal All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 25: Rotor Inspection
3. Mount the rotor in a pair of V-Blocks at the rotor bearing points. All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 26: Collector Ring Replacement
3. With a universal bearing puller, remove each collector ring one at a time from the rotor. (Figure 24) Figure 24 Collector Ring Removal All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 27: Alternator Assembly
(Figure 26) Figure 26 Spacer Ring Installation All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 28: Drive End Shield Assembly
Figure 28 Installing Rotor into Drive End Shield (1) Tool KDLJ 6018 (2) Support Ring All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 29: Collector Ring End Shield Assembly
8. Coat the inside of the collector end shield bore with Molycote. 9. Place sliding bushing into place on collector end shield. All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 30: Rectifier Assembly
1. Place flat washer and insulator (a) onto terminal B+ and D+ studs of the rectifier assembly. (Figure 32) Figure 32 Rectifier Insulators and Seal All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... - Page 31 11. Solder the soldering lug of terminal W to the solder pad of the rectifier assembly with rosin core solder. (Figure 34 ) Figure 34 Rectifier Mounting and Soldering of Terminal W All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98 T1ALTFinal.DOC...
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Page 32: Stator Assembly
7. Torque the drive end shield to collector end shield screws to 7.2 to 9.7 NM (21.2 to 28.3 in. lbs.). All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. -
Page 33: Regulator And Capacitor Installation
(Figure 37) Figure 37 Regulator Installation All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... - Page 34 8. Install air intake cover onto alternator. Do not torque cover until it has been installed on the vehicle/engine. All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp.
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Page 35: Functional Testing
All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 36: Power Output Test
2. Increase inductive load on the alternator until 76A output is achieved. As load is increased, monitor test bench speed and correct if speed drops while applying load. All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 37: Voltage Trace Evaluation
3. Turn on test bench and operate the alternator with a 10A load. 4. Compare oscilloscope display to the following test patterns. All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 38: Normal Pattern
In order to be able to compare oscilloscope images, the oscilloscope so the pattern fits between two vertical 10x divisions. Figure 40 Normal Pattern All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 39: Open Exciter Diode
This would require disassembly of the alternator and replacement of the rectifier assembly. Figure 41 Open Exciter Diode All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 40: Open Positive Rectifier Diode
With this type of defect, the rectifier assembly must be replaced. Figure 42 Open Positive Rectifier Diode All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 41: Open Negative Rectifier Diode
With this type of defect, the rectifier assembly must be replaced. Figure 43 Open Negative Rectifier Diode All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 42: Shorted Exciter Diode
This pattern identifies a shorted exciter diode. This would require disassembly of the alternator and replacement of the rectifier assembly. Figure 44 Shorted Exciter Diode All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 43: Shorted Positive Rectifier Diode
This pattern identifies a positive rectifier diode that is shorted. This defect requires replacement of the rectifier assembly. Figure 45 Shorted Positive Rectifier Diode All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 44: Shorted Negative Rectifier Diode
This pattern identifies a negative rectifier diode that is shorted. This defect requires replacement of the rectifier assembly. Figure 46 Shorted Negative Rectifier Diode All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98... -
Page 45: Open Phase Of Stator
This pattern illustrates a stator with an open phase winding. This type of defect would require replacement of the stator. Figure 47 Open Stator Phase All rights rest with Robert Bosch Corp, including patent rights. All rights of use of reproduction and publication rest with R. B. Corp. UA/ASV 04.12.98...