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Remanufactured alternator brush alignment #5346746 02/10/20 10:28 PM
Joined: Oct 2010
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wrcsixeight Offline OP
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Looks like they missed, badly.

Surprisingly it worked fine for 4.5 years like this~25k miles, and often, it was told by my adjustable voltage regulator, to make everything possible towards its 120 amp rating, feeding a large depleted low resistance AGM battery, over a thick copper circuit.


[Linked Image]
[Linked Image]

Re: Remanufactured alternator brush alignment [Re: wrcsixeight] #5346835 02/11/20 04:35 AM
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Linctex Offline
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Originally Posted by wrcsixeight
, and often, it was told by my adjustable voltage regulator, to make everything possible towards its 120 amp rating, feeding a large depleted low resistance AGM battery, over a thick copper circuit.


Almost sounds like the beginning story of a great off-grid energy project


https://www.microcogen.info/index.php?PHPSESSID=hlrq2sdhn8abq2afcbh4lubla5&board=12.0


"The evidence demands a verdict".
(Re:VOA)"it's nearly impossible to actually know the particular additives that are in there at what concentrations."
Re: Remanufactured alternator brush alignment [Re: wrcsixeight] #5346890 02/11/20 06:45 AM
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Donald Online Content
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In what country was the re-manufacture done?


2015 Ford F-250 w/Powerstroke
2016 Subaru Crosstrek CVT (wife's)
Re: Remanufactured alternator brush alignment [Re: wrcsixeight] #5347143 02/11/20 12:36 PM
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wrcsixeight Offline OP
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No idea where the remanufacturing occurred.

http://www.wilsonautoelectric.com/PartDetails/Index?partId=ba0d2bbc-44d3-4735-8b83-a567746add93

This was an O'reiley's sourced lifetime warranty replacement, and apparently was the last one they will give me.

It seemed more robust, output wise, than its predecessors, until that brush could no longer contact the slip ring.

The NEW Nippon Denso Alternator currently replacing it, is disappointing in output at hot idle speed.

I was led to believe it would be superior at hot idle, but it is not. Made in Malaysia, via AZ. I've not tested it for absolute max output, yet. but hot idle speed when brand new could barely keep up with loads at night, the Wilson had an extra 20 amps at hot idle for battery charging.

I've lowered brush holder and am truing up the slip rings, and gonna return the Wilson to duty once I give it some more spit and polish.



Re: Remanufactured alternator brush alignment [Re: wrcsixeight] #5347259 02/11/20 02:42 PM
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mk378 Offline
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Can you buy a set of brushes separately? Replace the brushes and put it together properly this time it'll be good to go.

Re: Remanufactured alternator brush alignment [Re: wrcsixeight] #5347770 02/12/20 02:13 AM
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wrcsixeight Offline OP
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Plenty of brush left.

Its the brush holder which was too high. I lowered it so lower brush is below gap and the whole thing sits more firmly than before

The top slip ring was way way out of round. Wound up spinning the rotor using a wire wheel cup on the Dual v belt pulley, using an angle grinder slowed way down via a Router PWm motor speed controller
Freshly disassembled:
[Linked Image]

Now:
[Linked Image]

I can't feel the rough looking parts on the slip rings. There is no more wobble of the slip ring. not sure how much better I can get it.



Re: Remanufactured alternator brush alignment [Re: Donald] #5348185 02/12/20 02:07 PM
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zzyzzx Offline
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Originally Posted by Donald
In what country was the re-manufacture done?


China or Mexico, I would assume.

Re: Remanufactured alternator brush alignment [Re: wrcsixeight] #5348536 02/12/20 08:25 PM
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wrcsixeight Offline OP
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[Linked Image]


Developed a better way to spin the alternator @ somewhat high rpm, in order to more precisely hone the slip rings.

Not perfect, but I don't want to remove more material, just to get the remaining grooves out. I can see em, but not feel them.



Re: Remanufactured alternator brush alignment [Re: wrcsixeight] #5348880 02/13/20 10:34 AM
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meep Offline
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This thread is great. Hands-on making it happen. Nicely done. Creative thinking with the wire-brush/pulley interface and PWM controller. Took some thinking to rig all that into place.

I'm wondering if they just didn't shim the commutator/armature properly, or was the brush holder bent?

-m


2018 F150
2015 crv (wifey!)
Re: Remanufactured alternator brush alignment [Re: wrcsixeight] #5348886 02/13/20 10:43 AM
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dogememe Offline
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Originally Posted by wrcsixeight
No idea where the remanufacturing occurred.

http://www.wilsonautoelectric.com/PartDetails/Index?partId=ba0d2bbc-44d3-4735-8b83-a567746add93

This was an O'reiley's sourced lifetime warranty replacement, and apparently was the last one they will give me.

It seemed more robust, output wise, than its predecessors, until that brush could no longer contact the slip ring.

The NEW Nippon Denso Alternator currently replacing it, is disappointing in output at hot idle speed.

I was led to believe it would be superior at hot idle, but it is not. Made in Malaysia, via AZ. I've not tested it for absolute max output, yet. but hot idle speed when brand new could barely keep up with loads at night, the Wilson had an extra 20 amps at hot idle for battery charging.

I've lowered brush holder and am truing up the slip rings, and gonna return the Wilson to duty once I give it some more spit and polish.


What do you mean the last one they will give you? As long as you aren't obviously abusing the warranties you can get it replaced repeatedly. Of course if you took it apart before trying to warranty it...


2010 Ford Escape 2.5 ~102K Miles: Castrol Magnatec 5W-20, Wix Filter.
2001 Chevy Suburban 5.3 ~290K Miles: Valvoline Maxlife 10W-30, ACDelco Filter.
Re: Remanufactured alternator brush alignment [Re: wrcsixeight] #5348987 02/13/20 12:48 PM
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wrcsixeight Offline OP
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I did not open it up until well after they said they had no record of me ever buying an alternator. Spent a good amount of time on the phone and they had me and my new and old phone numbers, and other parts I bought on file, but no Alternator.

This lifetime warranty kept me from bothering to open it up and satisfy my curiosity, or look for units better inline with my demands. I had gotten no less than 6 alternators on it since 2004/5.

This alternator just has one nut and the whole black plastic cover comes off though, revealing the rectifier and brush holder. It did not have paint or a sticker to indicate tampering.

The slip rings were either set too low on the shaft, or the brush holder, if replaced with a new part, was not dimensioned correctly.

I shortened the legs of the brush holder, and the base of it now resides on the machined flats containing the bearing, instead of a MM above it.



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