Repair the generator from Bosch

Dismantling

To disassemble the generator, proceed as follows:

- Unscrew the nut 1 (Fig. 320) from the shaft of the rotor and pulley off the shaft 3, as well as fan and remote washer. The shaft in the loosening can be fixed to a pulley on which to install the old serpentine belt and clamp it in a vise, as shown in Fig. 321. You can also insert Allen key into the end of the shaft and nut. For removal of a pulley puller should be used with two or three jaws. It should be remembered that the set pulley chosen specifically for this model engine;

- Removed from the shaft Woodruff;

- Unscrew and remove the regulator along with the brush assembly;

- Mark the bearing cover on the drive side and the housing in the opposite locations of the housing and unscrew the two tie rods. Separate the rear cover from the front bearing cover. To do this, the front cover of the bearing can be easily obstuchal plastic hammer;

- Install the bearing cap and the rotor under the press and remove the rotor puller with three claws, as shown in Fig. 322. When pressing out the rotor can be damaged by the bolts of the bearing. So be sure to sure that the capture of the three established under the bearing retainer, and not just under the hood. If you need to remove the bearing from the cover, unscrewing the screws on the inside and press out the bearing;

- Remove bearing puller with the rear end of the rotor shaft. When using the stripper grabs it should be installed under the bearing inner ring;

- Unsolder the diodes block from the stator. To do this, grab a pair of pliers is held in place adhesions between the stator and a soldering iron, which will serve to dissipate heat. We can not allow the diodes to overheat.

Rectifier diodes should extract only the relevant special provisions and if there skills.

Check of brushes and brush holder

Check the carbon brushes for the presence of good contact with the slip rings. Check mobility brushes in guides if necessary to clean the brush holder gasoline or solvents.

If the brush is worn to a height of 5 mm (Fig. 323), it should be replaced.

Control of the rotor

If the slip rings are dirty, clean them with a cloth soaked in gasoline. If you find scratches have to be deleted, which use the finest emery cloth grain. In case of heavy wear rings should be replaced by a rotor.

To check the insulation resistance of the windings to make test probe ohmmeter to the rotor core, and the other probe to the contact rings (Fig. 324). If the reading does not correspond to "infinity", the rotor should be replaced.

In order to control the passage of the rotor winding current to make the two ohmmeter probe to the contact rings (Fig. 325). The reading should be in the range of from 2.8 to 3.0 ohms. If the ohmmeter shows "infinity", there is a breakage in the windings, if the "0" - is short-circuited. If you notice any of these faults should be replaced by the rotor (Fig. 325).

Checking the stator

If a short circuit fault location can be set visually by burnout of the windings. In other cases, should make one ohmmeter test lead to the "hardware" - Set 1 (Fig. 326) of the plates, and the other - turn to one of the four terminals of the stator phases. The device should show "infinity." To check on the conductivity of the stator, in turn connect four output phase stator with each other. If there is no resistance, the current flow is broken (Fig. 327). The value of the insulation resistance should be 0.10-0.11 ohms.

Diode

The exact test diodes against voltage transmission and determine the value of the blocking current can only be done with a special tester, so the test is recommended in the service station.

Assembling the generator

When assembling it is necessary to use the figure. 320. Before installing the generator must be checked on the test bench in the electric repair shop of its charging capacity, operational reliability, etc.