ALTERNATOR NISSAN B13 with HARD TO FIND FAULT

This section I will explain hard to find fault as it was repaired, which is that the light of failure of the charging system lights up the board, "the  battery image", even with the switch off and especially at times high humidity or rain. Apart from being intermittent. Not sufficient that the battery is discharged.

The following image shows only the alternator disassembly, do not show the procedure

 

After several armed / disarmed the alternator, not achieved against failure. This was revealed with a careful observation of the head housing screw terminal connection or main exit, where you can see a small part of the copper wire of the diode bridge, which is right at the apex of the screw, see the next picture.

IDENTIFIED FAILURE

Could be said that this would be easy to find fault with the tester, but this failure to present only when the rust on the screw separator, pictured below, is mixed with moisture and produce a short circuit to earth or ground primarily through diodes. In the photo above is also observed a break in the connection of a diode, I made to isolate and identify the fault.

Screw / terminal with traces of rust in the separator

The repair involves in the removal of a vertex roughing screw, in order to increase the distance and reduce possible contact

Reduced vertex screw

In addition to applying a coating of insulation that can be nail polish, to the discovery of copper conductor.

Repairs completed

Since this compensation is no longer presented the fault.

I think the Bosch`s quality control jump this detail.
And I do not know how many more alternators that are circulating in the street when they not find the fault, they decide or replace the entire alternator or diode bridge.

I hope they can use this experience to anyone in need.

I appreciate your comments

Tips and Tricks pencil-type soldering iron

Here some adjustments to make the most of our pencil-type soldering iron. in this case is for a 45W soldering iron.
The first is a temperature control, with the soldering iron of 45W and that sometimes requires a lower temperature at which this power can give, are adapted diode used as the 1N4007 and a night lamp switch.
Here the connection diagram.


As you can see is very simple and works as follows, When connected to an outlet and the switch is closed, alternating current is passed in its entirety by the soldering iron heater works 100%, thus obtaining the maximum temperature.
And when the switch is open alternating current can pass only half of the cycle, doing work the iron to about 50%, gaining almost half of its temperature.
Below some pictures

iron soldering and switch

connection details

final result

It should be noted that the switch only controls the temperature,but not disconnected from the electrical network, so it is necessary to disconnect from the mains to switch off.
Normally I connect to the switch is closed or on the soldering iron to heat quickly and then to 50% or opened.

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The following is adapted copper wire, I use a 14AWG gauge. This was done to get a lot thinner tip and extended to reach points where welds are more precious or difficult to access how the tracks of PC motherboards, mobile phones and others.

 



Note the point made with a diagonal cut to make it more fine.

So with the combination of the above adaptation is not necessary to have several soldering irons for different applications.
I hope this information is useful, for your comment thanks.