Repair and Testing Instructions for T1 Page 3
Alternator 0120 689 552 Edition 001
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
Table of contents
1 GENERAL ...............................................................................................................................................................5
2 SAFETY PRECAUTIONS.......................................................................................................................................6
2.1 SPECIAL TOOL USAGE..........................................................................................................................................6
2.2 FIRE RISK............................................................................................................................................................6
2.3 SKIN PROTECTION ...............................................................................................................................................6
2.4 COMPRESSED AIR ................................................................................................................................................6
2.5 EXPLOSION RISK..................................................................................................................................................6
3 SPECIFICATIONS..................................................................................................................................................7
3.1 ELECTRICAL TEST SPECIFICATIONS ......................................................................................................................7
3.2 MECHANICAL TEST SPECIFICATIONS.....................................................................................................................8
3.3 TIGHTENING TORQUES.........................................................................................................................................8
4 ALTERNATOR SCHEMATIC...............................................................................................................................9
5 ALTERNATOR CODING.....................................................................................................................................10
6 PARTS CLEANING ..............................................................................................................................................11
7 TOOLS, TEST EQUIPMENT LUBRICANTS AND ADHESIVES.....................................................................12
7.1 TEST EQUIPMENT ..............................................................................................................................................12
7.2 SPECIAL TOOLS .................................................................................................................................................12
7.3 LUBRICANTS AND ADHESIVES ............................................................................................................................13
7.3.1 Lubricant Quantities.................................................................................................................................13
8 EXPLODED VIEW................................................................................................................................................14
9 ALTERNATOR DISASSEMBLY AND TESTING..............................................................................................15
9.1 REAR COVER REMOVAL .....................................................................................................................................15
9.2 VOLTAGE REGULATOR REMOVAL.......................................................................................................................15
9.2.1 Brush Replacement...................................................................................................................................16
9.3 NOISE SUPPRESSION CAPACITOR TESTING AND REMOVAL....................................................................................16
9.4 PULLEY AND FAN REMOVAL...............................................................................................................................17
9.5 SEPARATION OF DRIVE SHIELD AND COLLECTOR END SHIELD .............................................................................17
9.6 RECTIFIER ASSEMBLY TESTING..........................................................................................................................18
9.7 REMOVAL AND TESTING OF STATOR ASSEMBLY..................................................................................................19
9.8 RECTIFIER ASSEMBLY REMOVAL........................................................................................................................20
9.9 DAMPENING RESISTOR TESTING AND REMOVAL..................................................................................................21
9.10 REMOVAL OF COLLECTOR END SHIELD BEARING AND SEAL.................................................................................21
9.11 REMOVAL OF SLIDING BUSHING IN COLLECTOR END SHIELD ...............................................................................22
9.12 REMOVAL OF ROTOR FROM DRIVE END SHIELD...................................................................................................22
9.13 REMOVAL OF BEARING AND SEAL FROM DRIVE END SHIELD................................................................................24
9.14 REMOVAL OF COLLECTOR RING END INNER BEARING RACE FROM ROTOR............................................................24
9.15 ROTOR INSPECTION ...........................................................................................................................................25
9.16 COLLECTOR RING REPLACEMENT.......................................................................................................................26
10 ALTERNATOR ASSEMBLY............................................................................................................................27
10.1 ROTOR ASSEMBLY.............................................................................................................................................27
10.2 DRIVE END SHIELD ASSEMBLY...........................................................................................................................28
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