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  #1  
Old 12-17-2007, 10:27 AM
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Lu47Dan Lu47Dan is offline
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Exclamation Alternator rebuild and conversion

To make a long story short the regulator for the generator on my Super-H quit on me a week or so ago . To buy a new one was $35 , and it was never meant to run five lights and keep the battery charged . JEGS had a "One wire" rebuild kit for a 10SI Delco-Remy alternator for the same price , I ordered the kit last Saturday and received it on Tuesday . The first step was to tear the alternator down and clean it up .
  1. Alternator , front
  2. Side
  3. Rear
  4. Inside rear housing
  5. Stator ring
This alternator was the dirtiest , nastiest one I had . If you attempt this rebuild make sure you take a picture of the internal layout of the rear housing , so you can refer to it when you go to re-assemble the parts . The internals were pretty much toast in this alternator . I checked the stator and the rotor for dead shorts and they were alright . Dan
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  #2  
Old 12-17-2007, 10:31 AM
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Lu47Dan Lu47Dan is offline
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  1. Rotor
  2. Rear case stripped
  3. Front case stripped
  4. Fan
  5. Pulley
Next step is to run these parts through the parts washer to remove the caked in dust and oil . Dan
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__________________
Tools to Men are like Shoes to Women , you can never have too many !!
Used diesel engines are an adventure anyway you look at them !!
Miller XMT-304 Multiprocess
Miller 10-E Wire Feeder
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Hobart AC/DC stick welder
Hobart 175 Mig
Craftsman O/A set
Turbo torch and B-tank
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  #3  
Old 12-17-2007, 10:36 AM
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Lu47Dan Lu47Dan is offline
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Parts after cleaning and Glass bead blasting , first real test of the HF glass bead booth , I used it for one small part awhile ago and determined it needed a light inside it and installed one . Dan
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__________________
Tools to Men are like Shoes to Women , you can never have too many !!
Used diesel engines are an adventure anyway you look at them !!
Miller XMT-304 Multiprocess
Miller 10-E Wire Feeder
Miller Spectrum 2050 Plasma Cutter
Hobart AC/DC stick welder
Hobart 175 Mig
Craftsman O/A set
Turbo torch and B-tank
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  #4  
Old 12-17-2007, 10:39 AM
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Lu47Dan Lu47Dan is offline
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I painted the pulley and the fan Rustoleum Sunrise Red , the only red I had in a spray can . The cases were clear coated . Dan
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__________________
Tools to Men are like Shoes to Women , you can never have too many !!
Used diesel engines are an adventure anyway you look at them !!
Miller XMT-304 Multiprocess
Miller 10-E Wire Feeder
Miller Spectrum 2050 Plasma Cutter
Hobart AC/DC stick welder
Hobart 175 Mig
Craftsman O/A set
Turbo torch and B-tank
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  #5  
Old 12-17-2007, 10:56 AM
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Lu47Dan Lu47Dan is offline
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Smile Re-assembly

The kit comes with instructions on the re-assembly steps read and follow the steps !
First step is to install the bearings , rear bearing is installed flush to the outside of the bearing boss on the case , front bearing is a slip fit in this front case and is help in place with a retaining plate .
Second step is to install the regulator and brush holder . Included in the kit are two new retaining screws and plastic isolation bushings these go in specific places , this is why you took the pictures of the internals of the rear case ! Once you install one of the new screws and bushings , reuse the un-bushed screw from the old assembly in it's matching hole in the new assembly . Install the new rectifier and diode trio ,but don't put the nuts on like it shows in the picture , install the stator ring onto the rectifier and install the nuts . Tighten and check ALL your connections . Dan
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__________________
Tools to Men are like Shoes to Women , you can never have too many !!
Used diesel engines are an adventure anyway you look at them !!
Miller XMT-304 Multiprocess
Miller 10-E Wire Feeder
Miller Spectrum 2050 Plasma Cutter
Hobart AC/DC stick welder
Hobart 175 Mig
Craftsman O/A set
Turbo torch and B-tank
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  #6  
Old 12-17-2007, 11:04 AM
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Shade Tree Welder Shade Tree Welder is online now
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Quote:
Originally Posted by Lu47Dan View Post
...on my Super-H quit on me a week or so ago. ...JEGS had a "One wire" rebuild kit for a 10SI Delco-Remy alternator...
One question it is pretty tight up there under the hood of the "H's" will the alternator fit in there?

Nice work on the rebuild.
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  #7  
Old 12-17-2007, 11:11 AM
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Lu47Dan Lu47Dan is offline
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Before dropping the rotor in to place slide the wire holding the brushes compressed to the outside of the case so there is only about a quarter inch left sticking out of the brush holder inside the case .
Drop the rotor in place and align the front case the way you want the power stud oriented . Flip the alternator over and install the bolts that hold the cases together , tighten the bolts and flip the case over again .
Install the fan spacer .
Install the fan , lock washer and nut , tighten nut . Spin the rotor it won't spin will out some resistance but should spin fairly easily . Dan
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__________________
Tools to Men are like Shoes to Women , you can never have too many !!
Used diesel engines are an adventure anyway you look at them !!
Miller XMT-304 Multiprocess
Miller 10-E Wire Feeder
Miller Spectrum 2050 Plasma Cutter
Hobart AC/DC stick welder
Hobart 175 Mig
Craftsman O/A set
Turbo torch and B-tank
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  #8  
Old 12-17-2007, 11:14 AM
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Lu47Dan Lu47Dan is offline
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Shade if it doesn't fit , I have plan two also . I will build a mount to mount it on the governor housing on the other side of the engine . I think it will be pretty tight under the hood , but we will see . Dan
__________________
Tools to Men are like Shoes to Women , you can never have too many !!
Used diesel engines are an adventure anyway you look at them !!
Miller XMT-304 Multiprocess
Miller 10-E Wire Feeder
Miller Spectrum 2050 Plasma Cutter
Hobart AC/DC stick welder
Hobart 175 Mig
Craftsman O/A set
Turbo torch and B-tank
Reply With Quote
  #9  
Old 12-17-2007, 11:31 AM
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Lu47Dan Lu47Dan is offline
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Once you have checked and made sure that the rotor spins freely you can pull the wire holding the brushes compressed out .
Then the rubber cap that came with the kit is installed of the spade terminals for the regulator . Finished , ready to install .
  1. Wire
  2. Rubber cap
  3. Rubber cap installed
  4. Front
  5. Rear
There are a few things you will have to determine when you first tear the alternator down , one is the condition of the slip rings on the rotor as long as they are smooth , they are probably alright , pits and other defects lead to shortened brush life . Clean the slip rings with a abrasive cloth rated for electrical equipment such as Electro-cut . Check the general condition of the case for cracks , etc. If you have any questions about the stator and the rotor find a shop and have them check them out , most will charge a small fee but it usually still ends up being cheaper than if they did the rebuild . Dan
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__________________
Tools to Men are like Shoes to Women , you can never have too many !!
Used diesel engines are an adventure anyway you look at them !!
Miller XMT-304 Multiprocess
Miller 10-E Wire Feeder
Miller Spectrum 2050 Plasma Cutter
Hobart AC/DC stick welder
Hobart 175 Mig
Craftsman O/A set
Turbo torch and B-tank
Reply With Quote
  #10  
Old 12-17-2007, 11:35 AM
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What does the kit comprise of? We have a glass bead machine here at work and I've used it to clean up several items. Makes them look new.
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