HELP: Charge and Sediment light on, no charge to battery

Technical questions and answers about the Mazda Bongo

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mikeonb4c
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HELP: Charge and Sediment light on, no charge to battery

Post by mikeonb4c » Thu Oct 11, 2012 12:25 pm

Damn. Just when I needed the uber-reliable Bongo to go away in tomorrow, I’ve come out to find charge and sediment lights staying on with engine running (even when revved) and no apparaent charge to the SB (voltage stays at 12v approx with engine off and engine on). Couldn’t do more in the rain before I had to take the bus to work (I could have risked the 10 miles there and back I guess but thought better of it). Also, phoned Adrian at Japan Direct for gave me some thoughts but is off work for a week so can’t attend to it just now.

So…..I’ve had a quick look at old threads and it seems:

1. I need to check voltage at alternator to make absolutely sure it is giving out no charge
2. Need to check belts are OK (but suspect they will be)

I’m puzzled that this appears to have happened suddenly. You’d think an alternator might fade slowly so that first indication was charge light being slow to go out, but going out when engine revved.

Now, assuming I find the alternator is giving out no charge, how do I ascertain if it is the alternator or the alternator regulator (which I read could be a cause). Or even something else? I saw on one thread that a bad earth can cause a problem, though this sounds like an outside chance and I think the person in question had a flickering charge light rather than charge light permanently on.

Next, I have a spare alternator bought from Harry a few years back just in case, but can I easily tell from some label on its casing whether it is suitably rated (Bongos need 90amps? 100amps?) as no point fitting an lower-rated one it seems.

If I have to change the alternator, does it make sense to fit new belts at the same time or does that up the complexity of the work (bearing in mind I might even attempt to do this tomorrow morning so I can set off mid afternoon if I get it fixed).

Also, I have an alarm bell about the tensioner being very hard to undo and likely to break. Am I stuffed if this happens or can I rig up a make-do. And I thought I read a thread where someone had sourced replacements.

And what is the technique for getting the alternator set so tension in the belts is correct?

Finally, is an old geezer with a bit of tennis elbow and a back that doesn’t much like being bent over, going to be able to DIY this job or should I take it in to be done? And with Adrian out of action, where to? Wheelquick are usually rushed off their feet.

I know most if not all this stuff is out there on threads, but it is so scattered and anecdotal that its hard to assemble with certainly.

Oh and finally, how long y'da reckon a diesel Bongo would run on SB + LB power combined if both were well charged and only min. electrical devices were used?

Any thoughts would be very gratefully received.

Thanks chums. I’m missing the Bongo already :cry:
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Re: HELP: Charge and Sediment light on, no charge to battery

Post by wonkanoby » Thu Oct 11, 2012 12:46 pm

get it wacked on

its spanner work

so any competent spanner man if your backs not up to it

a good rule of thumb is 1/2 inch deflection in longest run for any belt

another is you should be able to twist it 90 degree
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Re: HELP: Charge and Sediment light on, no charge to battery

Post by g8dhe » Thu Oct 11, 2012 12:59 pm

Just check that your Headlamps come on first as the Image also powers the alternator, if this fuse fails (Headlamp blown ?) then no magnetic field within the alternator to generate anything!
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Re: HELP: Charge and Sediment light on, no charge to battery

Post by mikeonb4c » Thu Oct 11, 2012 1:02 pm

wonkanoby wrote:get it wacked on

its spanner work

so any competent spanner man if your backs not up to it

a good rule of thumb is 1/2 inch deflection in longest run for any belt

another is you should be able to twist it 90 degree
Thanks for getting back so quickly wonkanoby. I'm encouraged. Any local spannermen around tomorrow morning ha ha?

Any thoughts anyone on what to do if the tensioner bolt breaks (as it might well). How long do you reckon to do the job if all goes well? How to eliminate regulator as the cause (hat to change unit and find all still duff).
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Re: HELP: Charge and Sediment light on, no charge to battery

Post by Northern Bongolow » Thu Oct 11, 2012 1:46 pm

you cannot tell if the alternator or regulator has gone without the ness tackle. just swap the alternator as its all soldered inside and you need specialist tackle to repair/replace.
if the tensioner breaks you can simply put a nut and bolt in its place as a temp repair.

i will pm you my number if you want someone to hold your hand mike while you do the job. :wink:
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Re: HELP: Charge and Sediment light on, no charge to battery

Post by mikeonb4c » Thu Oct 11, 2012 2:55 pm

Northern Bongolow wrote:you cannot tell if the alternator or regulator has gone without the ness tackle. just swap the alternator as its all soldered inside and you need specialist tackle to repair/replace.
if the tensioner breaks you can simply put a nut and bolt in its place as a temp repair.

i will pm you my number if you want someone to hold your hand mike while you do the job. :wink:
As ever Ady, your are a total star (as is this whole bl**dy forum come to that - it never ceases to amaze me the support on tap when its needed). Are you around tomorrow morning because if so and if the old Bongo can make your place on a full battery charge (plus the PB could be put into parallel with it if need be using jump leads) then I might be tempted to whizz over. I can probably do these things on my own, but 1st time job for an old timer is a bit nailbiting and slow. Then again, it could actually wait (now I've calmed down a bit) as I can get a train over to my friends and the bus to work is easy, so Bongo could wait for a bit and it wouldn'r be a disaster. But yes, PM with your phone number would be great and I'll call either way. Thanks matey =D> =D>

PS - and your explanation of the regulator is a great help. If its inside the alternator, then its part of it as far as I'm concerned and I don't need to know whats wrong inside the unit - just swap it with Harry's old one. I might enjoy seeing if I can refurb the old one though. :roll:
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Re: HELP: Charge and Sediment light on, no charge to battery

Post by alan » Thu Oct 11, 2012 3:48 pm

hi mike i copy this from a post i put up when mine died on me an it was jaylee how found the new replacment part.
borke mine not undoing but doing up to heavy handed #-o
http://www.igmaynard.co.uk/bongo/forum/ ... =3&t=57631
OK, i(JAYLEE) went to this Mazda dealer in the village where i was brought up.. http://www.lansdownmazda.co.uk/contact.htm

Anyone enquiring regarding parts? Speak to a guy named Joe. Though i don't think he's that savy with Bongos, he does have an open mind!

Now the price.... If anyone knows cheaper please step up.. Bear in mind the Ford transit equivalent is about 40 quid!!!

FE3815966 BOLT ADJUST this part alone was £11.53.. In fairness you really only need this bit that sheers!?

The nut was £1.88

The long bolt £6.74...

Then there was the sharp intake of breath & the "dreaded Vee Aye Tee"...

It was an up front gamble on my part, but the return was peace of mind with the belts..
take it easy drive a bongo
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Re: HELP: Charge and Sediment light on, no charge to battery

Post by mikeonb4c » Thu Oct 11, 2012 4:32 pm

alan wrote:hi mike i copy this from a post i put up when mine died on me an it was jaylee how found the new replacment part.
borke mine not undoing but doing up to heavy handed #-o
http://www.igmaynard.co.uk/bongo/forum/ ... =3&t=57631
OK, i(JAYLEE) went to this Mazda dealer in the village where i was brought up.. http://www.lansdownmazda.co.uk/contact.htm

Anyone enquiring regarding parts? Speak to a guy named Joe. Though i don't think he's that savy with Bongos, he does have an open mind!

Now the price.... If anyone knows cheaper please step up.. Bear in mind the Ford transit equivalent is about 40 quid!!!

FE3815966 BOLT ADJUST this part alone was £11.53.. In fairness you really only need this bit that sheers!?

The nut was £1.88

The long bolt £6.74...

Then there was the sharp intake of breath & the "dreaded Vee Aye Tee"...

It was an up front gamble on my part, but the return was peace of mind with the belts..
Thats brilliant Alan - yours was the post I'd seen a while back but couldn't find, but now I have the info thanks to you. If I break mine on the job :shock: I now know where to get a replacement pronto :P
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Re: HELP: Charge and Sediment light on, no charge to battery

Post by turbodave » Thu Oct 11, 2012 8:41 pm

Sorry Mike , as you have maybe told me before somewhere else, but where are you based? Dave
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Re: HELP: Charge and Sediment light on, no charge to battery

Post by mikeonb4c » Thu Oct 11, 2012 8:46 pm

turbodave wrote:Sorry Mike , as you have maybe told me before somewhere else, but where are you based? Dave
Hi Dave. I'm near Manchester Airport. Due to take the Bongo through the Peaks to Chesterfield tomorrow if I can either get alternator fixed or reckon it could manage 50 miles without a charging system. Question then is do I feel lucky, as Dirty Harry said ha ha. I may start on it tomorrow a.m. and take the train if I can't get it fixed. Just bad timing really. Grrrrrr.
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Re: HELP: Charge and Sediment light on, no charge to battery

Post by turbodave » Thu Oct 11, 2012 10:24 pm

Hi Mike, The reason I ask is that my local garage is friendly, reliable and has worked on a couple of Bongos , including mine...and its on your way to Chesterfield! Dave
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Re: HELP: Charge and Sediment light on, no charge to battery

Post by mikeonb4c » Thu Oct 11, 2012 10:41 pm

turbodave wrote:Hi Mike, The reason I ask is that my local garage is friendly, reliable and has worked on a couple of Bongos , including mine...and its on your way to Chesterfield! Dave
Ooh now that's interesting. If you had a phone number I could phone them in the morning on the off chance they could do it while I waited, if I dropped in. I wonder if the Bongo will easily do the distance on SB power with LB (and its a powerful one) linked in as backup. Thanks a lot for this Dave, could be a lifeline.
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Re: HELP: Charge and Sediment light on, no charge to battery

Post by mikeonb4c » Fri Oct 12, 2012 8:58 am

A huge 'up' for Turbodave. He's given me a garage en route to my destination that will look at the job if I drop in. So I'm going to go for it, as i'm short on time, health and opportunity to DIY it. Will keep you posted, and thanks again Dave and to all who offered advice and help.
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Re: HELP: Charge and Sediment light on, no charge to battery

Post by MarcT77 » Fri Oct 12, 2012 9:14 am

Mike,
Just a quick word to boost your confidence sans alternator,I ran my Transit (recently px'd for the Freda) without a
functioning alternator for over a month,I just carried a spare fully charged battery around with me
and kept everything drawing current switched off,i.e radio,heater fan etc,I managed a good 3-4 days driving to work
7 miles before I had to re-charge the battery,though this did start to become a worry as the nights drew in
and I started night shift....turning those headlights on gave me palpitations.
I became a dab hand at not using the brakes unless absolutely necessary as well..neutral at traffic lights etc.

If i didnt have to go to bed (I'm overdue now) I'd wizz over to give you a hand,my back is slightly less
creaky than yours by the sound of it... :mrgreen:
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Re: HELP: Charge and Sediment light on, no charge to battery

Post by MarcT77 » Fri Oct 12, 2012 9:18 am

Oh yeah,might be a bit late now if you're getting it done today,but a liberal spraying of plusgas
on the tensioner and left overnight might help to calm your fears also....
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