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Date: Sat, 22 Jan 2005 06:39:03 -0600
From: Charlie England <ceengland@bellsouth.net>
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To: Rotary motors in aircraft <flyrotary@lancaironline.net>
Subject: Re: [FlyRotary] alternator problem fixed
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Paul wrote:

> Well, I finally solved my alternator problem. Just a quick recap of 
> events...First, the alternator blew a 70 amp fuse.  Flew a couple of 
> short flights with alternator inoperative. Started checking wiring. 
> Had 12 volts at alternator plug (the one that excites the field).  
> Decided to remove alternator and purchase a new one.  I brought the 
> alternator to O'Reilly Autoparts, where they put it on their test 
> machine and it was only putting out 9volts.  alternator not in 
> stock...They would have to order one.  Went to CarQuest. Same 
> problem....special order.  While I was at the counter, and playing 
> with the alternator, I noticed that the vanes on the cooling fan were 
> shiny. Further inspection showed qouges out ot the fins. Further 
> inspection showed a screw inside the housing that was wedged into the 
> windings.  (I had taken this alternator to a local alternator/starter 
> rebuilding shop a month earlier).  I brought it back to him, he took 
> it apart, trashed the bad parts and sent me on my way with a newly 
> repaired alternator and an appoloy.  I reinstalled the alternator on 
> my plane, fired it up and it now indicates 14 volts while the engine 
> is running.   I believe that the screw that went through the fins and 
> jammed into the field wiring had a detrimental effect on the 
> alternator, and probably contributed to the fuse blowing as well.  The 
> screw was originally one of four that were inside the alternator. The 
> other 3 were tight. The one that came loose and caused all the havoc 
> came out because the insulator that it held in place was cracked.  
> Paul, got the electrons flowing again, Conner


And *that's* why you fuse the alt wire (at the battery end). A short in 
the alt will draw the full amps available from the battery & turn the 
wire into a fuse if you don't.

Charlie