that lincoln Ranger 9 I got some months ago wouldnt charge the battery. There was a melted wire going down into the fan shroud, and Ive been putting off fixing it for months. It ran fine, just wouldnt charge. So this weekend I decided to bust it open and find out what happened..
(you can use the zoom button to get a closeup of the damage)
It looks like something, probably the coil pack clamp bolt (missing) got down into the backside of the flywheel/fan and into the stator of the battery charging generator (alternator?)
One of the leads was melted all the way back to the stator and melted off the solid state gizmo (voltage regulator?), and some of the windings had gotten mighty toasty. Ohmed windings to the laminations shows a dead short..and with the bashed laminations, its not suprising.
I figure I can use a dremal tool and cut off the bashed lamination sections, and get them out of the winding insulation. what do i do for some sort of "dope' to paint over the bare/dinged etc etc windings?
Im going to have to make up a crimp and crimp on a new wire to replace the burned away one and then put both wires into some sort of sheath material. The original vinyl sheath having melted away and needed cutting away.
It didnt do the magnets on the inside of the flywheel all that much good either, but they are plastic type magnets and for the most part are all there and nothing is loose, after I took out the busted chunks...cringe....
If I have to..I could rewind the entire stator..it doesnt look all that complicated....but the laminations were covered with a thin layer of black plastic before being wound...might require wrapping with paper? and rewinding over them......
I dont know how much Lincoln wants for a new assembly...but its gotta be damned expensive...so its field expediant repair or nothing.
All you coil winding tranformer making electicamal types gots some seegestions?
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