Z22SE Alternator Repair

evocarlos

so got real bored with the rain not letting me fix my blowing exhaust
i moved in to the batcave and took an alternator apart to see about fixing it 🙂
bearing #1 off

slip rings look good

bearing #2 off

with a new regulator and bearings this would be a working alternator 🙂

if you have any dead ones about PM me 🙂

evocarlos

new bearings

main case bearing hole

new main bearing fitted

new rear bearing fitted and a coat of VHT on the innards

retaining screws refitted

all bolted back together and spinning nice

next step to bench test it 🙂

evocarlos

bench test results 🙂
elec drill and a battery
the rig lol

12.7v static charge

no load 14.33v charging 🙂

evocarlos

https://www.youtube.com/watch?v=53RQUgKSsvI

Matt

Mind if I put this into a Resource on here Carl?

evocarlos

Matt said:
Mind if I put this into a Resource on here Carl?

nope 🙂

Matt

Cheers buddy.

Matt

Matt submitted a new resource:

Z22SE Alternator Repair - Fix a broken alternator

so got real bored with the rain not letting me fix my blowing exhaust
i moved in to the batcave and took an alternator apart to see about fixing it 🙂
bearing #1 off
[ATTACH]39484[/ATTACH]

slip rings look good
[ATTACH]39485[/ATTACH]

bearing #2 off
[ATTACH]39486[/ATTACH]

with a new regulator and bearings this would be a working alternator 🙂
[ATTACH]39487[/ATTACH]

if you have any dead ones about PM me 🙂

new bearings
[ATTACH]39488[/ATTACH]

main case bearing hole
[ATTACH]39489[/ATTACH]...

Matt

Done (y)

IDI_AMIN

So whats the cost of the new bearings carlos
I thought of dismantling one myself a couple months back when mine died on me but couldn't get it apart then after a short scan on the net i found out it could be the regulator thats done. ialso thought you could maybe open up the regulator and put new brushes in there but couldnt get that open either .Have you tried that yourself.
I know that a lot of electric spinning tools have the carbon brushes in them and when they are worn the machine will stop turning whatever it is ,so thats why i thought you could do the same with the alternator just stick in new carbon brushes and it would be alright again

evocarlos

bearings were about £15 for the pair i got heavy duty skf so they were a bit more £ over the standard type bearing
there are 2 main things that can fail
1 - diode pack
2 - regulator

the diode pack can be tested with a multimeter while its fitted to the alternator its easy to show if there are any dead you can either replace the diode pack or replace the individual diodes as long as its not bunt the mounts most likely easier to replace the hole pack

the regulator is the most common thing to go and are quite cheap to replace and only 3 screws that hold it on and the brushes are part of the regulator 🙂

evocarlos

next one came today but got bumped in the post

you can see at some point the +12v cable has been shorted melting the casing

with the rear cover removed the regulator and diode pack is shown

with the regulator removed you can see this one has short brushes

the wear is also visible on the slip rings

this alternator has a clutch pulley that seams to be defective as it spins both ways with out locking

https://www.youtube.com/watch?v=FC9_FJG0k0Q

evocarlos

had to take this one apart from the back side 1st the pulley was unremovable
the diode pack on the right you can see the diodes pushed in to the alloy case

the coils of enameled wire

accidentally broke the bearing slip ring cover

to get the pulley off i ended up welding the inner and outer parts to make it solid then clamp the shaft in the vice and then tackled it with stilsons

then took the slip rings off as there done

same black paint on the innards to stop more rust

and the case

need to order new slip rings then it will get rebuilt 🙂

Dave_Gilbert

very good carl i like how detailed you are(y)

Dave_One

Carl,

Buddy, need your help. What wires come off the alternator, in particular charging? I'm thinking of using a split charge system to remotely control my Car PC without draining the car 🙂.

Cheers,
Dave

evocarlos

Dave One said:
Carl,

Buddy, need your help. What wires come off the alternator, in particular charging? I'm thinking of using a split charge system to remotely control my Car PC without draining the car 🙂.

Cheers,
Dave

blue/white i think its in the connector infornt of the relay box

IDI_AMIN

Carlos do you have a link to a place for a new set of bearings been looking on e bay and seen some but not quite sure if they are proper size etc . as you have done this im sure you would have a better idea correct size or is there a standard size that would fit all.
Had a major nightmare yesterday going from Stirling back to Glasgow after a night shift. a half hour journey that turned into a 4 hour + episode. my alternator packed up on me and it was only in about 4 months . Last time i replaced mine it lasted a couple of years so i would like to rebuild one to hopefully avoid this happening again

evocarlos

IDI AMIN said:
Carlos do you have a link to a place for a new set of bearings been looking on e bay and seen some but not quite sure if they are proper size etc . as you have done this im sure you would have a better idea correct size or is there a standard size that would fit all.
Had a major nightmare yesterday going from Stirling back to Glasgow after a night shift. a half hour journey that turned into a 4 hour + episode. my alternator packed up on me and it was only in about 4 months . Last time i replaced mine it lasted a couple of years so i would like to rebuild one to hopefully avoid this happening again

slip rings
http://www.ebay.co.uk/itm/151128783583?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

bearing and slip ring kit
http://www.ebay.co.uk/itm/150800623860?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

the regulator you will have to contact him about i got one locally for £25 bnib
he also sells the diode pack 🙂

IDI_AMIN

Cheers Carlos(y)