Bosch T1 Alternator, Repair And Testing Instructions

Page 1: ...tor 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 Repair and Testing Instructions for T1 Alternator 0120 689 552 ...

Page 2: ... 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 Modifications Edition Date Name Modifications 001 8 28 98 I Serra Original 002 12 4 98 I Serra Update 8 98 Instructions ...

Page 3: ...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 1...

Page 4: ...7 REGULATOR AND CAPACITOR INSTALLATION 33 11 FUNCTIONAL TESTING 35 11 1 GENERAL INFORMATION 35 11 1 1 Power Output Tests 35 11 1 2 Voltage Trace Evaluation 35 11 2 POWER OUTPUT TESTING 35 11 2 1 Test Bench Mounting 35 11 2 2 Power Output Test 36 11 3 VOLTAGE TRACE EVALUATION 37 11 3 1 Oscilloscope Hook up 37 11 3 2 Normal Pattern 38 11 3 3 Open Exciter Diode 39 11 3 4 Open Positive Rectifier Diode...

Page 5: ...rights All rights of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC 1 General This manual contains repair and testing instructions with corresponding test specifications for the 0 120 689 5 series alternators T1 RL 28V 70 140A Note Alternator 0 120 689 543 was utilized in preparing these instructions ...

Page 6: ...ression the alternator is equipped with capacitors with a long storage time Cleaning of alternator components may cause and electrical discharge when they are immersed in cleaning fluid This discharge may cause combustible liquids to ignite 2 3 Skin Protection To avoid skin irritation when handling oils and greases apply protective gloves or creams before starting work and wash off hands with soap...

Page 7: ...istance 7 5 W 0 10 T1 RL 28V70 140A Power Output Test Alternator Speed RPM Load Current Inductive A Test Duration Min 1500 76 30 T1 RL 28V70 140 A 6000 136 10 Following completion of the output test allow alternator to run at 7000 rpm for one minute Oscilloscope Pattern This image represents a properly functioning alternator The D C voltage produced has a small harmonic wave Small spikes may be su...

Page 8: ...9 in Collector ring diameter Used 31 5 mm 1 240 in minimum New 16 0 mm 0 630 in minimum Carbon Brush Projection Used 7 0 mm 0 275 in minimum 3 3 Tightening Torques Item Number Description Metric Nm SAE 55 Air Intake Stud 3 0 3 4 26 5 30 1 in lbs 66 D Terminal 2 4 3 2 21 2 28 3 in lbs 29 B Terminal B Terminal 10 0 13 0 88 5 115 in lbs 37 W Terminal 4 1 5 5 36 3 48 7 in lbs 15 Voltage Regulator 1 3 ...

Page 9: ...s All rights of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC 4 Alternator Schematic Figure 3 Alternator Voltage Regulator Schematic 1 Alternator B Battery Positive B Battery Negative D Dynamo Warning Lamp Output W Tachometer Output 2 Voltage Regulator D Dynamo Alternator Output DF Dynamo Field D Dynamo ...

Page 10: ...12 98 T1ALTFinal DOC 5 Alternator Coding T 1 R 28V 70 140A Rated current in amps measured at 6000 rpm Rated current in amps measured at 1500 rpm Alternator Voltage Direction of Rotation Or R Clockwise Or L Counter Clockwise Or RL Multidirectional 1 Claw Pole Alternator 2 Salient Pole Alternator 3 Windingless Rotor Alternator Outer Diameter of Alternator G 100 109 mm K 120 129 mm N 130 139 mm T 170...

Page 11: ...rnator components may cause and electrical discharge when they are immersed in cleaning fluid This discharge may cause combustible liquids to ignite Alternator components with capacitors should only be cleaned with a non combustible cleaner such as HAKU 1025 6 Caution Compressed Air Only use compressed air regulated to a maximum of 4 Bar 60 PSI and a clean cloth for cleaning of the armature excita...

Page 12: ...9 0 986 619 362 Die Spigot for Arbor Press Used with KDLJ 6011 KDLJ 6012 KDLJ 6015 KDLJ 6010 0 986 618 124 Bearing Remover KDLJ 6009 0 986 618 121 Press Tool for Roller Bearing KDLJ 6021 0 986 618 139 Bearing and Seal Installer KDLJ 6011 0 986 618 125 Collector Ring Installer KDLJ 6012 0 986 618 126 Drive End Shield Support Ring for Rotor Pressing KDLJ 6013 0 986 618 127 Press Tool Spacer Ring Rol...

Page 13: ...Final DOC 7 3 Lubricants and Adhesives Description Manufacturer Number Bosch Number UNIREX N3 5 975 560 125 Ft1 v 34 5 700 009 000 Roller Bearing Grease VS 15164 Ft 5 975 560 000 Molycote Paste Ft 70 v 1 5 700 040 000 Adhesive Dispersant KK57v1 5 703 151 000 Silicon Paste Ft2v4 5 700 083 005 7 3 1 Lubricant Quantities Bottom of Roller Bearing 2 g 0 07 oz Collector End Shield Radial Seal 2 g 0 07 o...

Page 14: ...Ball Bearing 3 Cover Plate 6 Rotor 6 9 Collector Ring 10 Roller Bearing 11 Collector Ring End Shield 12 Rectifier 12 13 Seal 15 Washer Screw Assembly 17 Transistor Regulator 17 3 8 Compression Spring 17 3 801 Carbon Brush Set 17 10 Gasket 18 Stator 19 Spring Lock Washer Item Designation 20 Plain Washer 21 Oval Head Screw 23 Washer Screw Assembly 42 Suppression Capacitor 43 Oval Head Screw 53 Fan 5...

Page 15: ... air intake cover Figure 5 Figure 5 Air Intake Cover Removal 1 Note The voltage regulator must be removed before any further disassembly of the alternator takes place The brushes of the regulator can break if the regulator is not removed before any other disassembly takes place 9 2 Voltage Regulator Removal 1 Remove the three 3 screws that secure the regulator to the collector ring end shield Figu...

Page 16: ... 7 mm 0 276 the brush must be replaced Figure 7 2 To replace the brushes the brush lead must be unsoldered and the brush removed from the regulator 3 Insert the new brush into the regulator and solder the brush lead to the regulator Note Use only rosin core solder to attached the brush lead 4 Check the brushes for freedom of movement after they are soldered 5 Measure the exposed length of the new ...

Page 17: ...or the capacitor lead should be shorted to the capacitor mounting strip to discharge the capacitor Failure to do so may cause the capacitor to discharge while being cleaned 9 4 Pulley and Fan Removal 1 Using a 14 mm hex socket to hold the rotor shaft Loosen and remove pulley retaining nut with a box wrench Figure 9 Note Do not use an air impact gun to remove the nut as the force of the impact may ...

Page 18: ...s to be performed a Using tester WPG 012 00 Bosch Number 0 684 201 200 Figure 11 i Connect the negative black lead of the tester to the collector end shield and the positive red lead to each of the stator connection solder joints ii Connect the positive red lead of the tester to the B Terminal and the negative black lead to each of the stator connection solder joints iii Connect the positive red l...

Page 19: ...he stator connection solder joints No current should pass through the rectifier assembly vi Connect the negative black lead of the tester to the D Terminal and the positive red lead to each of the stator connection solder joints Current should pass through the rectifier assembly If the rectifier assembly fails any test one or more of the diodes are defective and the whole assembly must be replaced...

Page 20: ...xterior of the stator indicates a breakdown of the stator insulation and a short to ground If continuity is present the stator must be replaced 9 8 Rectifier Assembly Removal 1 Loosen and remove the three screws that hold the rectifier to the collector end shield Figure 14 2 Unsolder the W terminal from the rectifier assembly 3 Remove the nuts holding terminals B B and D to the collector end shiel...

Page 21: ...ld read between 3 1 and 3 5 k kilohm If the resistance is above or below this range the W terminal is to be replaced as an assembly Figure 15 2 Loosen the nut retaining terminal W to the collector end shield 3 Remove terminal W 9 10 Removal of Collector End Shield Bearing and Seal 1 Insert extractor KDLJ 6009 Bosch Number 0 986 618 121 into bearing 2 Screw threaded rod KDAW 9995 14 Bosch Number 0 ...

Page 22: ...aded rod KDAW 9995 14 into extractor KDAW 9995 6 f Slide the receiver cup KDAW 9995 0 5 onto threaded rod g Screw on handle and rotate until the bearing race comes out of the collector end shield 9 11 Removal of Sliding Bushing in Collector End Shield 1 Place collector end shield in an arbor press support mounting pivot boss on mandrel KDLJ 6016 Bosch Number 0 986 618 130 Figure 17 2 Place bushing...

Page 23: ... DOC 3 Press out rotor 4 Remove spacer ring from rotor shaft Notes Protect the threads of the rotor from damage prior to pressing Always replace the drive end bearing if the rotor has been pressed out Therefore only remove the rotor if the rotor is to be replaced the excitation winding of the rotor is to be replaced the drive end bearing spacer ring is to be serviced the rotor collector rings are ...

Page 24: ...aring from the drive end shield 9 14 Removal of Collector Ring End Inner Bearing Race from Rotor 1 With a universal bearing puller remove the inner race of the endshield bearing Figure 20 Notes Place jaws of the puller yoke behind the inner bearing race and pull the bearing race only Do not place the yoke behind the spacer ring Pulling both the bearing and the spacer ring at the same time may dama...

Page 25: ... 21 2 Using insulation tester KDAW 9983 or equivalent apply 80 VAC to the rotor claw poles and each of the collector rings If the insulation tester lights there is a short to ground within the rotor Figure 22 Note The insulation tester applies a voltage of 80 VAC to the rotor Voltages of 80V can be fatal When performing this test observe care is used in handling the rotor and any component or surf...

Page 26: ...st be replaced b Each collector ring maximum run out 0 03 mm 0 0012 in If the run out exceeds the maximum the collector rings can be machined down to a minimum of 31 5 mm 1 240 in diameter If the required machining causes the collector ring diameter to drop below the minimum dimension the collector ring s must be replaced 9 16 Collector Ring Replacement 1 Before the collector rings can be removed ...

Page 27: ... lead for the rotor windings does not become damaged while sliding the collector rings over the lead 4 Lining up the slot in tool KDLJ 6012 Bosch Number 0 986 618 126 with the rotor lead press the collector rings onto the rotor as far as possible Figure 25 5 Solder each of the rotor winding leads to one of the collector rings with rosin core solder 6 After soldering touch up surface of collector r...

Page 28: ...mbly 1 Insert sealed ball bearing into the drive end shield 2 Align the holes of the bearing cover plate with the holes in the drive end shield 3 Start the four screws which hold the bearing cover plate and tighten to 4 1 5 5 Nm 36 3 48 7 in lbs Figure 27 4 Insert bearing fan spacer ring into the drive end shield from the fan side of the shield 5 Place drive end shield on to an arbor press with th...

Page 29: ...k the bottom of the collector end housing bearing bore with an additional 2 g 0 07 oz of UNIREX N3 grease 5 Coat the sealing lip of the radial lip seal and pack the seal with 2 g 0 07 oz of UNIREX N3 grease Notes Do not assemble the alternator with a dry radial seal as this will lead to seal failure and contamination of the brushes and collector rings Make sure there is no excess grease on the ext...

Page 30: ...e 30 11 Insert terminal W into collector end shield in location marked W Make sure the locating lug of the terminal assembly indexes the end shield correctly 12 Place insulator and flat washer onto terminal W 13 Install nut and torque to 4 1 to 5 5 Nm 36 3 to 48 7 in lbs 14 Install protective cap onto terminal W Figure 31 Protective Cap 10 4 Rectifier Assembly 1 Place flat washer and insulator a o...

Page 31: ...lating washer flat washer and nut to terminal studs B and D Figure 33 6 Install flat washer and nut onto terminal stud B Figure 33 7 Check that the soldering lug of terminal W is still in the proper location of the rectifier assembly 8 Torque terminal stud nuts B D and B to a Terminal B and B 10 to 13 Nm 88 5 to 115 in lbs b Terminal D 2 4 to 3 2 Nm 21 2 to 28 3 in lbs 9 Install the flat washer an...

Page 32: ...ator leads to the rectifier assembly with rosin core solder 10 6 Rotor and Drive End Shield Installation 1 Place collector end shield and stator assembly on a suitable surface so the rotor and drive end shield assembly can be lowered into place 2 Guide the rotor and drive end shield assembly until the inner bearing race of the collector end bearing enters the roller bearing Once the inner race ent...

Page 33: ...s heard the rotor and drive end shield assembly must be removed the cause determined and repaired before continuing Once the problem has been corrected start at step 1 of this section 11 Remove the alignment pin KDLJ 6014 from the alternator 10 7 Regulator and Capacitor Installation 1 Depress the carbon brush closest to the regulator into the regulator brush holder 2 Insert a straightened paper cl...

Page 34: ...en aligning the mounting holes pay attention to the force used as damage can occur to the brushes 5 Install the three 3 regulator mounting screws and torque to 1 3 to 1 7 Nm 11 5 to 15 in lbs Figure 38 6 Install capacitor on collector end shield and tighten mounting screw to 4 3 to 5 7 Nm 38 0 to 50 4 in lbs Figure 38 7 Connect lead of capacitor to spade terminal 8 Install air intake cover onto al...

Page 35: ...g minimum criteria Characteristic Minimum Specification Variable Speed Control 0 12 000 RPM Drive Motor 4 kW 5 4 hp Load Bank Capability 170 A 28 V for 10 minutes 80 A 28 V for 30 minutes Output Voltage Capability 28 V 11 1 2 Voltage Trace Evaluation The voltage trace evaluation compares the output of the alternator as viewed on an oscilloscope to know oscilloscope patterns The voltage trace evalu...

Page 36: ...to test bench manufacturers operating instructions for correct terminology of test leads Refer to figure 39 for a schematic outline of alternator to test bench connections Compare this schematic to the hook up schematic of your test bench 4 Make sure the test bench is set for the correct voltage and rotation before starting tests 11 2 2 Power Output Test 1 Start test bench and increase speed to 15...

Page 37: ...ternator output and speed during the test period 9 Remove load and operate the alternator at 7000 rpm for one minute to allow the alternator to cool 10 Refer to the test bench operating instructions and allow the load bank to cool the required amount of time before proceeding to the next test 11 Apply a minimum load of 10A to the alternator 12 Measure the regulated voltage of the alternator The co...

Page 38: ...3 2 Normal Pattern This image represents a properly functioning alternator The D C voltage produced has a small harmonic wave Small spikes may be superimposed on the oscilloscope screen if the voltage regulator is regulating Applying a load to the alternator output terminals can turn off the regulator In order to be able to compare oscilloscope images the oscilloscope so the pattern fits between t...

Page 39: ...ghts of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC 11 3 3 Open Exciter Diode This pattern displays a characteristic dip in the normally smooth wave characteristic of a defective exciter diode This would require disassembly of the alternator and replacement of the rectifier assembly Figure 41 Open Exciter Diode ...

Page 40: ...1ALTFinal DOC 11 3 4 Open Positive Rectifier Diode This pattern identifies an open positive rectifier diode In the case of multiple diodes in parallel all of the diodes on the circuit must be open An example is There are two diodes in the rectifier for each phase of the stator Both diodes must be open for this pattern to appear With this type of defect the rectifier assembly must be replaced Figur...

Page 41: ...1ALTFinal DOC 11 3 5 Open Negative Rectifier Diode This pattern identifies an open negative rectifier diode In the case of multiple diodes in parallel all of the diodes on the circuit must be open An example is There are two diodes in the rectifier for each phase of the stator Both diodes must be open for this pattern to appear With this type of defect the rectifier assembly must be replaced Figur...

Page 42: ...including patent rights All rights of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC 11 3 6 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 ...

Page 43: ...uding patent rights All rights of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC 11 3 7 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 ...

Page 44: ...uding patent rights All rights of use of reproduction and publication rest with R B Corp UA ASV 04 12 98 T1ALTFinal DOC 11 3 8 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 ...

Page 45: ... 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 11 3 9 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 ...