My alternator packed up, I had it rebuilt and then stupidly dropped a live wire on it and burnt the regulator and diodes out. I figured I would get a new one so went to the local auto electrician who supplies most of the Sydney north shore.

He had a nice 60 amp one which matched up so I took it up to the boat and found the power terminal fouled on the exhaust manifold. In the photo it looks like it just touches but when the alternator is tightened up it will foul a few mm more.

Unfortunately the electrician cannot find another match. I am tempted to cut the terminal down to its shortest length with the power lead held by one nut against the insulator. I need to measure it up accurately to see if it will clear when the terminal is cut down. Roughly how much clearance would I need?

If it doesn't I may be forced to have the 31 year old alternator rebuilt, again. It won't be any cheaper with the hours the electrician has put into this.

Any suggestions? Lord Howe decisions are getting close.

Hi Morningbird

Looking at the photo if there was enough clearance to the left of the alternator you could make a new (or extend the old) adjusting bracket and swing the alternator further away from the engine and fit a longer belt

If you remove the inner nut that is against the insulator the stud might turn when you tighten the outer nut

Regards Don

You would want some clearance and make sure when you swing the alternator on its mounting that it cannot touch the manifold . so there no chance it could short out




www.balmar.net In this link Id say your is the first on the left

MorningBird said..

HG02 said..
You would want some clearance and make sure when you swing the alternator on its mounting that it cannot touch the manifold . so there no chance it could short out




www.balmar.net In this link Id say your is the first on the left

Agreed HG. The alternator in the photo has a 2" saddle mount. It is a 60 amp Mitsubishi alternator, the Sole is a Mitsubishi based engine.

if its the two inch maybe a Bosch would fit off a Holden below Bosch K1 off roughly 1990 statesmen 90 amp but you can buy lower
You could check ut a local wrecker just take your original with you for sizing so you can Identify

someday said..
An idea is to try undoing the bolts that hold the front and the back of the alternator together,
and then seeing if it is possible to rotate and assemble them back together so that the
terminal is in a different position.

Hi Someday

Looking at the original photo it appears that the bottom mounting bolt that the alternator pivots on goes through both the front and rear housings so they can only go in the original position on the engine

Regards Don

Hi Someday

In the photo that HG posted of the Bosch one on his Bukh you could probably do it as it only mounts on the front housing but i am fairly sure from what Morningbird has said when he described it as a saddle mounting that his mounts on both the front and rear housings

Regards Don

Weld a section into the top adjustable bracket so that the alternator is clear and use a longer belt. Pick up a plastic cover for the terminal from a wrecking yard.

Life wasn't meant to be easy MB

I got it solved today. As usual it turned out to be simple was better. It is yet to be wired in, planned for tomorrow afternoon.
I'm not good on electrics but I didn't want to go above 60 amps on my little 20hp engine. I expected that anything bigger would be difficult to fit and put undue load on the engine.

I changed belts. Having cut the terminal down after the electrician said it would be ok I found the adjusting strap was too short. I got a longer strap from the auto electrician but then got out a spare belt that was smaller than the previous one and it all came together. I think I prematurely got concerned at all the fiddling I was doing to get it on and missed the obvious.
Of course the boat electrician might look at it tomorrow and tell me it is all wrong. I doubt it but I hate electric string and the stuff hanging off it.

Good Stuff M.B.
Wish I could say Ill see you at Lord Howe but i cant not for a couple of years yet.

Good job MB. I've found a good mobile mechanic who does the Pittwater area too. Very handy.
Hope the Lord Howe trip goes well for you. Missus and I haven't got out of Pittwater yet.