Static test of Denso 12 V alternator

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Discussion Overview

The discussion revolves around the testing and evaluation of a Denso A127 12V alternator, which was removed from a JCB wheel digger due to charging issues. Participants share their experiences and methods for bench testing the alternator, including assessments of its components such as the regulator, rectifier, rotor, and stator. The conversation includes both theoretical and practical aspects of alternator functionality.

Discussion Character

  • Exploratory
  • Technical explanation
  • Debate/contested

Main Points Raised

  • One participant describes their testing process, including checking the regulator, rectifier, rotor, and stator, and expresses confidence in the alternator's condition pending a dynamic test.
  • Another participant suggests that common failures in alternators often stem from worn brushes or dirt in the brush holders, and mentions the possibility of rotor shorts occurring only when spinning.
  • There is a proposal to conduct a load test by connecting the alternator to a motor to see if it can maintain appropriate voltage levels under load.
  • One participant questions the configuration of the stator windings, suggesting it might be delta-configured, while another proposes it is likely WYE-configured based on their experiences.
  • Discussion includes the use of a meter to test for shorts to casing, with some participants agreeing that measuring conductance in nanosiemens could be useful for detecting high resistance shorts.
  • Historical context is provided regarding older automotive alternators and their operational characteristics, including the importance of certain components like the bootstrap resistor and the implications of wiring configurations.

Areas of Agreement / Disagreement

Participants express differing views on the stator configuration, with some suggesting it is WYE while others consider it could be delta. There is no consensus on the exact nature of the alternator's issues or the best testing methods, indicating ongoing debate and exploration of ideas.

Contextual Notes

Participants mention various assumptions about the alternator's condition and functionality, but there are unresolved questions regarding the specific wiring configuration and the effectiveness of proposed testing methods. The discussion reflects a range of experiences and knowledge levels regarding alternator mechanics.

Who May Find This Useful

This discussion may be of interest to individuals involved in automotive repair, particularly those working with alternators, as well as hobbyists looking to understand the testing and evaluation of electrical components in vehicles.

  • #31
Tom.G said:
Yup, intermittent coil-to-coil short. Hope you can find a motor rewind or alternator repair shop nearby. It's possible to do it yourself but kinda touchy, and often hard to get the right size wire and insulating paper if used.

Please keep us updated.
Sadly, the little old rewind shops are getting rare these days. Since I assume a bad stator is a less common fault than, say, a bad rectifier or regulator, I may be able to find another similar unit and make two into one.

Anyway, I can bide my time now as the old dynamo is back on line!

I'll certainly post an update - very frustrating to view a thread that is not resolved.
 
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  • #32
Guineafowl said:
It doesn't read shorted with the multimeter now, but if I squeeze the coils gently the reading will jump around a lot.

Sometimes, if you're lucky,...
you can poke the winding with a soft wood stick (ladies' orange stick for cuticle maintenance work well) and get the wires separated .
Then saturate the winding with varnish.
Proper material would be electrical varnish or industrial "Glyptol" electric motor paint made for the purpose.
I have had success with both Polyurethane wood furniture varnish from the hardware store and high temperature engine enamel from the auto parts store. For under the hood i think i'd prefer the engine enamel.
 
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