Bosch Starters And Alternators

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Comprehensive range coveringPassenger, Commercial,Heavy Duty, Stationary Engines,Marine & Common Spare PartsStarter Motors and AlternatorsFor Australia & New Zealand2010 2011

Invented for LifeFrom the verybeginning, Bosch’shistory has beencharacterisedby a drive forinnovation andsocial commitment.Environmental andsocial responsibilitiesare core values atBosch. Our slogan“Invented for life”conveys the ambitiousstandards we haveset ourselves andthe values that wehave long stood for.“Invented for life”stands for reliabletechnology designedand built to last.At the same time itembodies innovationsand technologythat contribute tothe conservation ofresources, sustainabledevelopment, andhelping peopleimprove their qualityof life.The Robert BoschStiftung (RobertBosch Foundation)was established in1964 to keep alivethe philanthropic andsocial endeavours of itsfounder Robert Bosch.Through its programsand institutes, thefoundation has sinceissued 840 millioneuros in project funds.In 2007, it madeavailable 58.9 millioneuros for non-profitprojects. Education,internationalunderstanding, andpublic welfare are thetop priorities statedin Robert Bosch’s willand are the pillars ofour work today.Responsibility for theenvironment is a corevalue at Bosch and isfirmly anchored in ourprinciples for safetyand environmentalprotection. Ourenvironmental focusesare on renewableenergies, energyefficiency, andemissions reduction.At Bosch we believewe have an obligationto develop innovativeand beneficialtechnology and inorder to meet suchdemands, considerableamounts of moneyare spent each yearon research anddevelopment. Weemploy more than25,000 researchand developmentassociates worldwide,all working towardsthe creation oftechnology that isinnovative, beneficialand environmentallyfriendly. COPYRIGHT 2010 – Robert Bosch (Australia) Pty LtdAll rights reserved. No part of this publication may be reproduced ortransmitted in any form or by any means, electronic or otherwise including,without limitation, photocopying or recording without permission in writingfrom the copyright owner. All details, illustrations and specificationscontained in this publication are based on the latest information available atthe time of printing. Whilst every precaution is taken to ensure the accuracyof the content, Robert Bosch (Australia) Pty Ltd accepts no responsibility forany errors or omissions.

Starter Motors & AlternatorsProduct InformationApplicationA2The Bosch Automotive StoryA4IntroductionA6Starter MotorsA8Alternators - Universal and EuropeanA10Alternators - Australian and AsianA12Alternators - Liquid Cooled and RefrigerationA14Alternators - Long HaulA16Basic Alternator Test ProcedureA18Marketing MaterialsA19General Warranty InformationB1How to Use This CatalogueB2Vehicle ApplicationsB505 Refrigeration ApplicationsVisual IdentificationGuideC2Alternators - Quick Find IndexC4Alternators - Visual Identification Guide - How to UseC151 Universal Alternators - Visual Identification GuideC162 Alternator Performance CurvesC166 Alternator Pulley ConfigurationsC168 Starter Motors - Quick Find IndexC170 Starter Motors - Visual Identification Guide - How to Use Spare PartsCross ReferenceD2Spare Parts - Visual Identification GuideE2Alternators - OE No. to 10 Digit No.E17Starter Motors - OE No. to 10 Digit No.An explanation of the special cases in the applicationssection (section B) can be found on the inside back cover.2010 2011Bosch Automotive Aftermarket

A2A 2 The Bosch Automotive StoryThe Bosch Automotive StoryThe Bosch Group is a leading global supplier oftechnology and services, with more than 300subsidiaries and regional companies in over50 countries.The beginnings were humble. In 1898 Robert Boschdeveloped a magneto ignition device and adapted itto suit a vehicle engine. In doing this he developedthe first reliable ignition system, solving one of thegreatest technical problems faced by the automotiveindustry at that time. This key innovation was thefirst chapter in the success story of Bosch as anautomotive supplier.From 1902 Bosch developed a high voltagemagneto ignition system incorporating spark plugs.While the magneto ignition has long since beenreplaced by battery ignition systems, Bosch todaymanufactures more than 300 million spark plugs peryear, using the very latest precious metal technology.As cars became a product for the masses, Boschrecognised the prospects for developing motorvehicle lighting. Research in this area resulted inthe launch of the Bosch automotive lighting system,comprising of headlights, a generator, a regulator anda battery. This was a significant milestone for bothBosch and the industry, being the first all-in-onesystem available to consumers, and also the basisfor components such as starters, horns, windshieldwipers, indicators and car heating systems to bedeveloped and added to the business.From about 1920, the growth of diesel enginesin trucks was a concern at Bosch, because dieselengines did not need an ignition system, thecompany’s main sales driver. To capitalise on thistechnological advance, Bosch began developing dieselinjection pumps and in 1936 launched the first dieselinjection pump for passenger cars. Today, Bosch isthe global leader in diesel technology, whether it befor passenger cars, trucks or injection systemsfor ships.In the years that followed, Bosch made numerousdevelopments with other automotive products.Gasoline injection systems were developed from1935 and by 1967 had all but displaced theBosch Automotive Aftermarketcarburettor. Braking systems have also been part ofthe Bosch offering since 1927. The introduction of theBosch ABS antilock braking system in 1978 was asignificant development in vehicle safety, laying afoundation for the development of further systems,such as Traction Control and the Electronic StabilityProgram (ESP ).In today’s market, vehicle manufacturers and serviceorganisations face the worldwide challenge ofefficient service for highly evolved vehicle systems.This includes not only mastering the electronicsystems in today’s automobiles, but also utilisingthe latest state-of-the-art diagnostics technologies toimprove servicing efficiencies. The growing range ofBosch diagnostic and service equipment delivers asophisticated solution for today’s workshops to meetthese challenges.Bosch spends billions of dollars annually in researchand development to preserve its position as atechnological leader. The company’s technologicalcompetence is evident in the fact that Bosch is worldleader in the number of automotive technology patentapplications it submits each year. Every hour Boschresearch teams create new patents to make Boschproducts safer, more efficient and moreenvironmentally friendly.As one of the world’s largest independentmanufacturers of automotive parts and systems,Bosch products and technology, supplied through aglobal network of factories, can be found on virtuallyevery make of car currently produced throughout theworld. This strong link to original equipmentdevelopment and innovation means Bosch is ableto deliver a superior aftermarket offering toits customers.With most vehicles on the road incorporating manyBosch manufactured components, it made sense forBosch to support these products with local servicecentres. The Bosch Service Network is a group of over14,000 independent workshops worldwide, offeringthe latest technical expertise, tools and equipmentto motorists.2010 2011

The Bosch Automotive Story A 3In just over a hundred years, Bosch successfullytransformed from a small automotive supplierinto a modern, multinational group, which todayhas a workforce of more than 270,000 peopleworldwide.Bosch employs over 2,300 associates in Australiaand New Zealand with activities spanning threebusiness sectors: Automotive Technology,Consumer Goods and Building Materials, andIndustrial Technology.During the past five decades Bosch has growninto a major force in the Australian automotiveindustry. Today, Robert Bosch Australia is nolonger a local company manufacturingautomotive components only for Australiancustomers. It is truly an integrated member ofthe Bosch global network supplying overseascustomers in Europe, Asia and America.In the automotive industry the name Boschis now synonymous with leading technology,sophisticated service solutions and high qualityreplacement parts.2010 2011Bosch Automotive Aftermarket

A4A 4 IntroductionThe Expertise of BoschFeature – Corrosion resistantBenefit – Longer life in harshconditionsFeature – Reduced sizeBenefit – Easy fitmentFeature – Reduction driveBenefit – Maintains continualspeeds for easier startingFeature – Injected aluminiumBenefit – Durability and long lifeBosch has unparalleled expertise in automotive electricalsystems. For over 100 years Bosch has been at thecutting edge of electrical technology and continuesto produce market-leading products to the highestquality standards. The commitment to quality is evidentin the range of Bosch starter motors and alternators.Manufactured to Original Equipment SpecificationsBosch starters and alternators are manufactured toOriginal Equipment Specifications to ensure correct firsttime fitment and reliable service for years to come.Bosch Automotive AftermarketSuitable for a Wide Range of ApplicationsBosch starters and alternators suit a wide rangeof applications including passenger cars, light andheavy commercial vehicles, construction equipment,agricultural machinery and stationary engines.Superior PerformanceBosch starters and alternators deliver superiorperformance, improved fuel economy and longer life.2010 2011

Introduction A 5Feature – Premium quality bearingsBenefit – Long lifeFeature – Non recycled copperBenefit – Less impurities forgreater performanceQuality in Every DetailCheaper starters and alternators may appear the same,but a closer look will reveal the superior quality andlong-term value of Bosch.High Quality ComponentsBosch use the highest quality raw materials in all oftheir starters and alternators to ensure long life andoptimal performance. In the range of starters, this meansinjected aluminium and corrosion resistant materials.In the alternator range it means premium bearings andnon-recycled copper.2010 2011Feature – Regulator designed forvehicle applicationBenefit – Long life and higherperformanceFeature – High quality raw materialsBenefit – Increased enduranceand reliabilityA Reputation that LastsBosch starters and alternators represent an investmentin quality which will deliver long-term value for both yourcustomer and your business. Why risk increased warrantycosts and damage to your workshop’s reputation by usinginferior products?Bosch Automotive Aftermarket

A6A 6 Starter MotorsStarter MotorsThe comprehensive range of Bosch starter motorscomprises long-life starter motors for spark-ignitionand diesel engines. All Bosch starters meet OriginalEquipment specifications to ensure long life and highperformance.Greater Efficiency and PowerIn order to manufacture compact, high-performancestarters, Bosch has reduced the size of the essentialstarter components and redeveloped them to maintainperformance. As a result, Bosch starters are easier toinstall and, more importantly, offer greater efficiencyand power.Bosch Automotive AftermarketComprehensive RangeBosch offers a comprehensive range of high qualitystarter motors for both passenger and commercialvehicles. Whether for gasoline or diesel engines,Bosch starters provide a high degree of reliabilityand performance coupled with a long working life.Genuine Bosch QualityWhen you purchase a genuine Bosch starter motor youare investing in a quality product with reliable warrantyand technical support.2010 2011

Starter Motors A 7Cutting Edge Start/Stop TechnologyBosch continues to lead the way in starter motordevelopment with Start/Stop technology. Designed inconjunction with some of the world’s leading automotivebrands, the Bosch Start/Stop System automatically stopsthe engine when the vehicle is stationary, for exampleat traffic lights, and restarts it as soon as the driver putsthe vehicle back into gear.The starter motor used in the system has beenspecifically designed to handle the increased numberof starts required, and enhanced meshing mechanicsensure that the engine runs quieter.2010 2011Bosch Start/Stop technology improves fuel efficiencyand reduces Co2 emissions, particularly on congestedcity streets where fuel savings of up to 15 percent canbe achieved. With fluctuating fuel costs and stricteremissions regulations, these savings are crucial.In developing Start/Stop technology, Bosch has onceagain demonstrated that it is the leader in starter motordevelopment. This leadership is evident across the entirerange of stater motors which provide reliable startingyear after year.Bosch Automotive Aftermarket

A 8 Universal Range of AlternatorsUniversal Range of AlternatorsBX Universal alternators suit a variety of automotiveapplications, particularly Australian, American andEnglish vehicles. Their higher amperage also makesthem ideal for agricultural and industrial applications.Bosch Automotive AftermarketBenefits of Bosch Universal alternators:4 Higher amperage4 Higher output allows continual operation4 Suits vehicles with aftermarket options4 Developed from Original Equipment technology2010 2011

European Range of Alternators A 9European Range of AlternatorsOnly an alternator that is precisely tailored to thevehicle’s specific electrical system can maximiseefficiency and economy. With unparalleled experiencein the development of alternators to suit Europeanapplications, Bosch is able to provide this precision anddeliver optimum performance for European vehicles.There is simply no better alternative.2010 2011Benefits of Bosch European alternators:4 Manufactured by the European experts from OriginalEquipment technology4 Manufactured using only premium-quality windingsand bearings4 All units are full-load tested to guarantee compliancewith Bosch’s strict performance specifications4 All units comply with the highest demands for poweroutput and efficiency4 Covers a wide range of European applicationsBosch Automotive Aftermarket

A 10A 10 Australian Range of AlternatorsAustralian Range of AlternatorsAustralian built vehicles continue to be some of themost popular on our roads. They owe their popularityto the fact that they are built for the unique drivingconditions of Australia which include extremetemperatures and long distances. The Bosch BXAustralian range provides quality alternators to suitthis range of vehicles.Bosch Automotive AftermarketBenefits of Bosch Australian alternators:4 Designed to withstand extreme Australiantemperatures4 Manufactured using only premium-quality windings,and bearings4 All units are full-load tested to guarantee compliancewith Bosch’s strict performance specifications4 All units meet Original Equipment specifications2010 2011

Asian Range of Alternators A 11Asian Range of AlternatorsAsian vehicles are becoming increasingly popular on ourroads. These vehicles are characterized by high efficiencyand performance and require a compact alternator thatstill delivers high output and high capacity. The Asianrange of Bosch alternators provides these performancecharacteristics, making them ideally suited to the mostpopular Asian imports.2010 2011Benefits of Bosch Asian alternators:4 Compact, low-noise alternators, designed specificallyfor Asian applications4 Manufactured using only premium-quality windings,and bearings4 All units are full-load tested to guarantee compliancewith Bosch’s strict performance specifications4 All units comply with the highest demands for poweroutput and efficiency4 All units meet Original Equipment specificationsBosch Automotive Aftermarket

A 12A 12 Liquid Cooled AlternatorsLiquid Cooled AlternatorsModern prestige vehicles include a high number ofelectrical components which place enormous strainon the alternator. Bosch liquid cooled alternators aredesigned specifically to handle the high electrical loadsof these vehicles.Liquid cooled alternators use coolant from the engine’scooling system which passes through a water jacketin the alternator, keeping the body and its electronicsoperating at a stable heat range. By using liquid ratherthan a fan, these alternators also offer the advantages ofwhisper quiet operation and reduced load on the engine.Bosch Automotive AftermarketBenefits of Bosch Liquid Cooled alternators:4 Direct replacement for Original Equipment4 Liquid cooled technology provides whisperquiet operation4 Designed to handle the higher electrical loadsof prestige vehicles4 All units are full-load tested to guarantee compliancewith Bosch’s strict performance specifications2010 2011

Refrigeration Alternators A 13Refrigeration AlternatorsBosch has developed three alternators specifically forrefrigeration trucks equipped with dual-temperaturerefrigeration units. These units feature heavy duty,high tolerance bearings, anti-corrosion coatings,a sealed brush box, a Zener diode rectifier plateand single mounting foot for increased service life.2010 2011Benefits of Bosch Refrigeration alternators:4 Original Equipment quality4 Designed to suit the high demands of refrigeratedtransport industry4 Built to fit application, no modification necessary4 Produces higher output at lower engine speeds4 Can be used in conjunction with battery sentinel unitsBosch Automotive Aftermarket

A 14A 14 Long Haul AlternatorsBosch Heavy Duty Output AlternatorsBosch Long Haul alternators feature high efficiencyalternator technology which delivers maximum chargingpower over the long-haul. With 160/200 Amps on-the-roadoutput and 80/120 Amps at idle, these alternators providesuperior output under all operating conditions.Longer Battery LifeBosch Long Haul alternators represent the nextgeneration of heavy vehicle charging technology,delivering more power and greater efficiency thancompetitive alternators. Bosch’s higher charge rateat idle helps maximise battery life by reducingbattery cycling.Bosch Automotive AftermarketHigh Temperature ResistanceSeveral features allow Bosch units to withstand operatingtemperatures up to 13% higher than competitive units.The amount of cooling air being pulled through the unitis maximised by dual internal cooling fans which draw airfrom both the front and the rear of the alternator forcingheat out through the vents circling the housing. The unitsalso feature long life bearing technology which combinesspecial heat-treated, long life steel bearings with heatresistant lubricant to better withstand heat and wear.At an operating temperature of 80 C, Bosch Long Haulalternators sustain superior operating amperage to supplymore power for critical electrical systems.2010 2011

Long Haul Alternators A 15Exclusive Self Protection TechnologyAmperage output is automatically reduced when underhood temperatures exceed 125 C, allowing the alternatorto continue to provide necessary power while protectinginternal components. Output returns to normal levelswhen the temperature drops below 125 C. Cooling isalso provided by an external heat dissipating rectifierwhich is mounted in the cool-air intake stream.Greater Efficiency and Lower Fuel ConsumptionHigh efficiency winding technology, using 30% morecopper than other units, increases efficiency and lowersfuel consumption. Heavy duty slip ring technology is alsoused to significantly reduce wear on the brushes.Benefits of Bosch Long Haul alternators:4 Higher charge rate at idle for longer battery life4 Built to withstand higher operating temperatures4 Self Protection Technology protects internalcomponents in extreme temperatures4 30% more copper provides increased efficiency andlower fuel consumption4 Reduced inventory with four part numbers replacingover 200 original equipment part numbers4 Direct replacement for Delco, Prestolite and LeeceNeville unitsFewer Part Numbers for Reduced InventoryWith only four part numbers replacing over 200 OriginalEquipment part numbers, inventory commitment can begreatly reduced.2010 2011Bosch Automotive Aftermarket

A 16A 16 Basic Alternator Test ProcedureBasic Alternator Test ProcedureSSLLB B Regulator Voltage TestOutput Current TestOutput Voltage Test1. Connect a voltmeter (0 – 20 volt) between thealternator B terminal and the alternator case(from ground connection).2. Connect an ammeter (refer Notes below) inseries with the alternator B battery cable.3. Start the engine and increase engine speedto 2000 RPM.4. Switch on or off headlights, etc. to adjust thecurrent load to show on the ammeter to between5 and 10 amps.5. Observe the voltage reading and record:4 If 13.8 to 14.5 volts. Test passed.4 If not 13.8 to 14.5 volts. Test failed.Output Voltage Test1. Record alternator Output Code stamped on thealternator casing: Example – 14V 17/85A. This is 17 amps at alternatorspeed of 1800 rpm and 85 amps at 6000 rpm.2. Connect a voltmeter (0 – 20 volt) between thealternator B terminal and the alternator case (fromground connection).3. Connect an ammeter (refer Notes below) in serieswith the alternator B battery cable.4. Start the engine and increase engine speed to 2500RPM. (approx. 6000 RPM alternator speed).5. Load the alternator by switching the headlights,etc. on to achieve a voltmeter reading of 13.5 volts.6. Observe the ammeter reading and record:4 If maximum alternator output current is achieved(as per 6000 alternator rpm related Output Code)test passed.4 If Output Code specification not achieved,test failed.Notes:A. With an inductive pick-up type ammeter (150A capacity) i.e. TECH 31 - PMS 100 or similar.B. With a standard ammeter (150 A capacity) bydisconnecting the battery lead from the B alternatorterminal and inserting the ammeter in series in thecorrect polarity.Bosch Automotive AftermarketNotes:A. With an inductive pick-up type ammeter (150A capacity) i.e. TECH 31 - PMS 100 or similar.B. With a standard ammeter (150 A capacity) bydisconnecting the battery lead from the B alternatorterminal and inserting the ammeter in series in thecorrect polarity.2010 2011

Alternator Test Procedure A 17SSLLB B Earth Circuit Voltage Drop TestCharge Line Voltage Drop TestOutput Voltage Test1. Connect a voltmeter (select the 1.0 volt scale)between the alternator case (ground) and thenegative (-) battery post (not the clamp).2. Start the engine and increase engine speed to2000 RPM.3. Switch on the headlights, etc. to load the alternatorto achieve a voltmeter reading of 13.5 volts.4. Observe the voltage reading and record:4 If less than 0.30 volt. Circuit is OK.4 If greater than 0.30 volt. Circuit has excessiveresistance (check connections, etc.).Output Voltage Test1. Connect a voltmeter (select the 1.0 volt scale)between the alternator B terminal and the positive( ) battery post (not the clamp).2. Start the engine and increase engine speed to 2500RPM.3. Switch on the headlights, etc. to load the alternatorto achieve a voltmeter reading (between the B andearth) of 13.5 volts.4. Observe the voltage reading and record:4 If less than 0.30 volt. Circuit is OK.4 If greater than 0.30 volt. Circuit has excessiveresistance (check connections, etc.).2010 2011Bosch Automotive Aftermarket

A 18A 18 Marketing MaterialsMarketing MaterialsThe following marketing materials are available to complement this catalogue.To obtain copies, please contact your Bosch distributor.Liquid Cooled Alternator Brochure4 page brochure listing applications forthe range of Liquid Cooled AlternatorsLong Haul Alternator Brochure6 page brochure highlightingthe performance features ofthe Long Haul RangeRefrigeration Alternator Application Guide8 page brochure providing technicalinformation and applications listingsfor refrigeration alternatorsVisual Identification Posters5 posters providing pictures and partnumbers of fast moving productswithin our Australian, European, Asian,Commercial and Spare Parts ranges.BX Poster Pack1 x A1 Vehicle application chart;4 x A2 Alternator series postersBosch Automotive Aftermarket2010 2011

Warranty A 19Robert Bosch AustraliaGeneral Warranty InformationIntroductionInitiating a ClaimAll products manufactured and/or sold by Bosch Australiacarry a statutory and voluntary warranty. Consumer’srights to such warranty are limited to failures and defectscaused by a material or manufacturing fault within thespecified warranty period.If a Bosch product fails within the specified warrantyperiod as a result of a manufacturing or material fault,consumers should:This warranty information describes very broadly thegeneral procedure for the settlement of warranty claims.Detailed information relating to the most commonlysubmitted non-warranty cases should also be reviewedprior to any warranty submission. Only genuine warrantycases are accepted.What is a Warranty Case?A warranty case exists when a Bosch product or sparepart fails within the specified warranty period as a resultof a manufacturing or material fault.What are Non-warranty Cases?A warranty case does not exist if the fault is causedby a violation of the operating, maintenance orinstallation instructions, inappropriate or improperuse, incorrect handling or unauthorised repairs andmodifications performed by third parties. Other examplesof non-warranty cases are failures caused by foreigncontamination and water entry.Natural Wear and TearDamage caused by natural wear and tear does notconstitute a warranty case even if it occurs within thewarranty period.Wrong Deliveries and Transit DamageWrong deliveries, incorrect or damaged packing andtransit damage claims are not warranty cases and will notbe processed as a warranty claim. Such cases should bedirected to Bosch Customer Service on 1300 30 70 40.Warranty Responsibility and EvaluationAll warranty claims are to be resolved in the mosteconomical and efficient way, either by repair orreplacement. In the case of Bosch starter motors andalternators, these must be sent to a Bosch AuthorisedService Dealer for warranty evaluation and/or repair.For details of your nearest Bosch Authorised ServiceDealer please call our hotline on 1300 060 060 or visitwww.bosch.com.au2010 20114 Stop using the goods4 Let the seller know as soon as possible4 Look after the goods until they are returned4 Return the goods, including proof of purchase(while there are no time limits, this should be doneas soon as possible).PackagingGoods do not have to be returned with the originalpackaging to obtain a refund.Warranty Periods and Proof of PurchaseThe warranty period begins from the date of sale to thecustomer (generally the consumer). The warranty periodis not renewed nor extended as a result of a warrantyrepair or with the supply of a replacement part. The selleris entitled to ask for proof of purchase when goods areclaimed under warranty and consumers are obligated toprovide proof of purchase when claiming goods underwarranty. Proof of purchase will generally indicate if thepurchased product is covered under warranty.The warranty period for Bosch starter motors andalternators is as follows:Passenger vehicle applications – 24 months/40,000kmCommercial vehicle applications – 12 months/20,000kmDeadlines for submitting Warranty ClaimsBosch Australia aims to rectify genuine quality problemsas a priority. This is generally achieved by investigatingwhy defective products have failed and by introducingimmediate corrective action measures to preventre-occuring warranty failures. It is therefore criticalthat all warranty cases are promptly reported to BoschAustralia. Bosch reserves the right to request the promptreturn of all defective parts.Product Liability and Product SafetyBosch Australia should be informed immediately aboutpotential product safety concerns within and outsidethe warranty period. Bosch Australia is well aware ofits product liability and product safety obligations andresponsibilities. It is our aim to ensure appropriateproduct safety standards are met in order to avoid injury,loss and damage caused by defects in Bosch products.Bosch Automotive Aftermarket

Bosch use the highest quality raw materials in all of their starters and alternators to ensure long life and optimal performance. In the range of starters, this means injected aluminium and corrosion resistant materials. In the alternator ran

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