GENERATOR (for BOSCH Made) INSPECTION


  1. INSPECT GENERATOR ROTOR ASSEMBLY


    1. A01E33I

      Check the rotor for an open circuit.


      1. Measure the resistance between the slip rings.

        Standard resistance
        1.8 to 2.8 Ω at 20°C (68°F)

        If the result is not as specified, replace the rotor assembly.

    2. A01E0XG

      Check if the rotor is grounded.


      1. Measure the resistance between each slip ring and the rotor.

        Standard resistance
        10 kΩ or higher

        If the result is not as specified, replace the rotor assembly.

    3. Check that the slip rings are not rough or scored.

      If rough or scored, replace the rotor assembly.

    4. A01E0WC

      Using a vernier caliper, measure the diameter of each slip ring.

      Standard diameter
      15.3 to 15.5 mm (0.602 to 0.610 in.)
      Minimum diameter
      14.9 mm (0.587 in.)

      If the diameter is less than the minimum, replace the rotor assembly.

  2. INSPECT GENERATOR STATOR SUB-ASSEMBLY WITH RECTIFIER

    A01DY3BE01

    Tech Tips

    For terminal positions of the generator stator, refer to the illustration above.


    1. A01DY5K

      Inspect the positive (+) rectifier.

      Tech Tips

      Inspect the positive terminal after pulling it up.


      1. Using an ohmmeter, connect one tester probe to each positive (+) terminal and the other to each rectifier terminal.

      2. Reverse the polarity of the tester probes and repeat the step above.

      3. Check that one polarity shows a resistance of below 1 Ω and the other shows a resistance of 10 kΩ or higher.

        If the result is not as specified, replace the generator stator sub-assembly with rectifier.

    2. A01DVBV

      Inspect the negative (-) rectifier.


      1. Using an ohmmeter, connect one tester probe to each negative (-) terminal and the other to each rectifier terminal.

      2. Reverse the polarity of the tester probes and repeat the step above.

      3. Check that one polarity shows a resistance of below 1 Ω and the other shows a resistance of 10 kΩ or higher.

        If the result is not as specified, replace the generator stator sub-assembly with rectifier.

    3. A01E11C

      Inspect the stator coil for an open circuit.


      1. Measure the resistance between the rectifier terminals.

        Standard resistance
        Below 1 Ω

        If the result is not as specified, replace the generator stator sub-assembly with rectifier.

  3. INSPECT BRUSH

    A01DVVZE01

    1. Using a vernier caliper, measure the exposed brush length.

      Standard exposed length of new brush
      13.2 mm (0.520 in.)
      Minimum exposed length
      6.0 mm (0.236 in.)

      If the exposed length is less than the minimum, replace the generator regulator assembly.

  4. INSPECT GENERATOR PULLEY WITH CLUTCH


    1. When rotating the pulley, check that it turns clockwise and that it does not turn counterclockwise.

      If the result is not as specified, replace the generator pulley with clutch.