E3L Dynamo refurbishment recommendations?

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Andy51
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E3L Dynamo refurbishment recommendations?

Post by Andy51 »

Hi All, after many trials and tribulations with intermittent charging (thanks to all who gave advice on this forum a few months ago), I have bitten the bullet and swapped dynamos - perfect charging! I now have an E3L Dynamo that requires a refurb (last done 12 or so years ago). It passed the normal tests at the time, the problem is intermittent, so replacement of components seems the way to go. I see that new armatures and field coils are available - is it worth trying the DIY approach given the hassle of refitting dynos on the singles if I don't get it right 1st time, or should I send it to a specialist? If so, any recommendations? Cheers, Andy
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Rob Harknett
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Re: E3L Dynamo refurbishment recommendations?

Post by Rob Harknett »

I have found it quite simple to fit new dynamo armature and brushes, also bearings. Never really had need to change anything else. Where you could hit problems is, refitting if you have solid state regulator. It seems 9/10 times rebuilding a dynamo, even refitting a new recon dynamo, polarity is reversed. After fitting you find you get no charge or sparks flying where they should not be flying. All due to blowing the solid state regulator by putting the wrong polarity through it. One of the boffins may tell you how to check the dynamo has the correct polarity. So you can avoid this problem. It caught me out when I got so far with the job and got called to the phone. I had the battery connect, which ended up draining to the dynamo and burning out my new recon dynamo. When I next decide to sort that bike out I will be fitting the old CVC unit, Then change back to solid state when it's working OK.
SPRIDDLER
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Re: E3L Dynamo refurbishment recommendations?

Post by SPRIDDLER »

Replacing the armature/bearings/brushes is a fairly straightforward job, but I believe replacing field coils (which I've never done nor had to do) is not for the faint-hearted and can be problematic.
If the field coils need replacing I'd recommend getting it all done by a specialist.

BTW - there are foreign made armatures (some under the Lucas brand name) at maybe half the price of U.K. manufactured ones but I prefer the U.K. made ones.
A specialist would probably fit a satisfactory and rewound armature, either your own or one from his stock.
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Radcap
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Re: E3L Dynamo refurbishment recommendations?

Post by Radcap »

I have just done mine . I got a full repair kit armature.field coil .brushes and bearings.
I had to buy a small bearing puller to remove the old bearings you need the shims behind them .
Strip down the old one and clean it out.
You need to check the space of the bearing with the shims for depth.
Rebuild it without the field coil 1st to get the bearing positions correct .
Dont over tighten the long screws keep checking the depth and there are gaskets on the end cover mine had 2 ,you need to reuse them ,keep trying it by hand that it spins
Easy and the rear bearing sit flush on the armature other wise you damage the case.
Once you are happy with this . Strip it down and fit the field coil 1st nip it up to agline it then refit the armature ,spin it and check its clear and does not catch the feild coil,
Then tighten the field coil screw realy realy tight this will pull it up and away from the armature.; dot punch the field coil retaning screw then fit the small screw that retains the feild coil screw.all the time check it spins freely.
Fit your brushes (take a photo before you strip so you have wires correct way )
Check the brushes run on the comutator evenly .
Bench test join the f and d conections together with a wire put you volt meter + wire on the f or d terminal put the neg on the body case .
Use a drill to spin it up 1st its important the you spin it the corect rotation for that model .start slowly and build the revs slowly .you should see the voltage rise to 12v +
Dont over rev it. To polarise it use you battery if its neg earth bike conect batt neg to body of the dynamo and with a wire gently touch the f terminal with the + from the battery you will get a small spark do this 2/3 times this is ready for a neg earth bike.
If its a poss earth bike put battery + to the body and neg to f.
If you want to check it works join the f and d terminal to batt poss conect batt neg to body . This will turn the dynamo in to a motor and it will turn .
Hope this helps . Take your time dont rush it.
56G80S
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Re: E3L Dynamo refurbishment recommendations?

Post by 56G80S »

Tony Cooper, didn't have details to hand but they are at:

http://www.totalbikebits.com/product_lo ... php?id=210

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Andy51
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Re: E3L Dynamo refurbishment recommendations?

Post by Andy51 »

Thanks, guys. This will give me food for thought. Cheers, Andy
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