I was inspecting my Mando 55A alternator wiring for corrosion etc this afternoon as I've noticed some fluctuations with alternator output lately.
This is the first time I've ever inspected properly as I was simply blissfully ignorant about such things until recently acquiring a shop manual.
Anyway....I pulled the rubber boot off the orange output lead connection and lots of rotten debris started to fall out. The terminal post exposed, I proceeded to unscrew the nut (gently) and SNAP! - the whole post just crumbled off the back of the unit
I'm tempted to pull the alternator unit off and try to repair the post by drilling it out and replacing as I know the alternator itself is working perfectly well. The recent output fluctuations are attributed to recently knocking the output cable whilst draining the cooling system. Only thing is, I have also noticed a small jumper wire now broken which went from a small black box about 20mm from the output post to the post itself. I can't tell the colour of this wire but suspect it may be a black ground? Is it worth my while attempting to salvage this unit or should I just install a nice shiny new one? It is 15 years old.
Also, Murphys (or is it sods?) law dictates that this should happen just before the weekend so I wont be able to get a new unit til Monday at the earliest. I notice its still possible to run the engine (idling anyway) without the alternator output and with two fully charged batteries on-board. Would I still be able to use the boat over this weekend without the alternator? Just for a short 10-15 mile round trip to the Admiral and mine's favourite island jetty?
Dave
This is the first time I've ever inspected properly as I was simply blissfully ignorant about such things until recently acquiring a shop manual.
Anyway....I pulled the rubber boot off the orange output lead connection and lots of rotten debris started to fall out. The terminal post exposed, I proceeded to unscrew the nut (gently) and SNAP! - the whole post just crumbled off the back of the unit

I'm tempted to pull the alternator unit off and try to repair the post by drilling it out and replacing as I know the alternator itself is working perfectly well. The recent output fluctuations are attributed to recently knocking the output cable whilst draining the cooling system. Only thing is, I have also noticed a small jumper wire now broken which went from a small black box about 20mm from the output post to the post itself. I can't tell the colour of this wire but suspect it may be a black ground? Is it worth my while attempting to salvage this unit or should I just install a nice shiny new one? It is 15 years old.
Also, Murphys (or is it sods?) law dictates that this should happen just before the weekend so I wont be able to get a new unit til Monday at the earliest. I notice its still possible to run the engine (idling anyway) without the alternator output and with two fully charged batteries on-board. Would I still be able to use the boat over this weekend without the alternator? Just for a short 10-15 mile round trip to the Admiral and mine's favourite island jetty?

Dave
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