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generator autopsy 120-130

uid 17774's pic
posted by  Damian on  Fri Apr 8 08:19 CST 2005
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Appears that there is problem with wiring inside generator, which might explain why the amp light wouldn't go out when I hooked up my old gen/ voltage regulator system.. Took thing apart, and found possible problem. Curious if this could be cause of failure.

I took pic of setup on red wire DF to show how it's supposed to be (I think). There are 2 round fiber washers which are positioned on outside of metal generator housing. The rectangular fiber washer (see yellow arrow) is positioned on inside of metal housing.

However, things aren't looking the same where threaded metal bolt (connected to blue wire D+) passes through hole on generator body. The 2 round fiber washers are there on ouside of body, BUT rectangular fiber washer on inside of housing is missing. Could this cause problem? I'm assuming those fiber washers are there on both sides of metal housing for a reason.

I know exactly when the fiber washer disintegrated, had the once stripped bolt rethreaded at hardware store to allow nut to go on correctly. When guy handed me genny, I saw pieces of fiber washer fall off.







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    generator autopsy 120-130

    posted by  Phil S. on  Fri Apr 8 12:02 CST 2005
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    last visit: Fri Oct 24 13:18 CST 2014
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    If the metal plate behind the threaded stud grounded to the housing, it definitely would explain not charging. Not sure how a Bosch is wired internally (there are two different schemes in common use), but you'd either get no output or unregulated high output.

    You'd also stand a good chance of toasting the voltage regulator.








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    generator autopsy 120-130

    posted by  someone claiming to be shayne on  Fri Apr 8 10:24 CST 2005 [RELATED]

    In my experience (and in the Haynes manual), DF always gets the GREEN wire.
    This is assuming you are using a stock wiring harness.

    Back to the drawing board:
    B+ on the regulator gets the thick black wire in the original harness.
    DF on generator and regulator gets the green wire.
    D+ on the regulator goes to D+ on the generator...red wire.
    D- is ground.








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    generator autopsy 120-130

    posted by  walrus3 on  Fri Apr 8 08:25 CST 2005
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    last visit: Mon Dec 2 14:20 CST 2013
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    As long as the wire and the bolt are adequately insulated from the housing
    it will be fine. I've used an assortment of fiber washers, pieces of plastic
    tubing, etc, to keep them apart. Also be sure everything is on good and TIGHT.
    --
    George Downs Bartlesville, Heart of the USA!







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