X-Virus-Scanned: clean according to Sophos on Logan.com Return-Path: Sender: To: lml@lancaironline.net Date: Fri, 19 Oct 2012 08:28:57 -0400 Message-ID: X-Original-Return-Path: Received: from mail-vc0-f180.google.com ([209.85.220.180] verified) by logan.com (CommuniGate Pro SMTP 6.0c2) with ESMTPS id 5832222 for lml@lancaironline.net; Thu, 18 Oct 2012 22:32:34 -0400 Received-SPF: pass receiver=logan.com; client-ip=209.85.220.180; envelope-from=billhogarty@gmail.com Received: by mail-vc0-f180.google.com with SMTP id fl13so8829819vcb.25 for ; Thu, 18 Oct 2012 19:31:57 -0700 (PDT) MIME-Version: 1.0 Received: by 10.52.69.47 with SMTP id b15mr14199261vdu.116.1350613916964; Thu, 18 Oct 2012 19:31:56 -0700 (PDT) Received: by 10.58.1.137 with HTTP; Thu, 18 Oct 2012 19:31:56 -0700 (PDT) In-Reply-To: References: X-Original-Date: Thu, 18 Oct 2012 19:31:56 -0700 X-Original-Message-ID: Subject: Re: [LML] TCM 60A alternator--diodes From: "William A. Hogarty" X-Original-To: Lancair Mailing List Content-Type: multipart/alternative; boundary=20cf307d03b0bfd6ef04cc604e6b --20cf307d03b0bfd6ef04cc604e6b Content-Type: text/plain; charset=ISO-8859-1 Paul: That was great info. Thank you for taking the time to send it. BTW, my coupling failed at about 25 Hrs. A quote for a new coupling was close to $ 1000. Fortunately, it was under warrenty. Easy to install. Regards, Bill H. On Wed, Oct 17, 2012 at 5:43 AM, Paul Miller wrote: > My primary alternator is original equipment TCM 60A alternator with 660 > hours. It should have been inspected at 500 hours but I deferred that. > This note suggests that the diodes get a check during that 500H > inspection. My secondary is a B&C 20A which was just replaced this year > after 600+ hours after some windings failed. I have had a lot of radio > noise but nothing so bad as to take steps to fix it. I had no idea that my > primary was only partially functioning. On this last trip from Calgary to > Texas and onto Florida, my primary was noted to have Zero output while > taxiing for takeoff at Midland TX. I flew using the secondary to charge > both busses for the two legs into Florida. After some testing I ruled out > the primary B&C regulator. Today, I tested the field resistance (15 ohms, > acceptable range should be 12-100 ohms) which was perfect. The field is > the rotor on this unit. I decided to pull the housing and check brushes > which were found to be almost perfect (90% remaining after 660 hours). > > The stator was uniform in color and not shorted. It pulls out easily for > inspection. The body of the alternator was not removed from the engine > making this test very fast and easy. A quick check revealed all six diodes > (two each for the three phases) had failed. Everything else was in > excellent condition. This unit is similar to the standard Delco Remy 10Si > alternator and shares many parts. The diode replacement from Aircraft > Spruce is almost $200. The new alternator is about $1400. A repair with > new rotor is about $500 including shipping and labor from a reputable shop > I spoke with. > > The diode assembly was sourced at my local shop with a spare set of > brushes for $20 total. These are 50A diodes (50A x 6 diodes) which is a > robust replacement satisfactory for even the 100A alternator. I had to > remove the B+ stud from the old diode assembly and press it into > replacement diode package. The re-assembly took about 20 minutes and it > fired up with 10A charge on low engine idle. This is much higher charge at > low idle than I can ever recall. > > This means that I've been flying for some time with less than 6 diodes. > I probably was flying on one or two phases and getting some radio noise > from the failed diodes. This may have been ongoing for years. Testing > diodes as part of a 500H inspection is simple to accomplish and guarantees > some margin for partial failure. I have photos I can markup and add for > reference in a follow up email. Here are the excellent contacts who helped > today: > > 1) TCM technical support 888.826.5465 Provided technical guidance and > emailed me the alternator service manual in PDF form (48p) without > hesitation. > 2) Bill at B&C Specialty, 316-283-8000, always helpful. Provided testing > procedure for regulator and the following reference for repair. > 3) Aircraft Systems, Rockford IL, 815-399-0225 TCM alternator repair > specialists > 4) Rupp Auto, New Smyrna Beach, bench testing, parts and expert on 10Si > alternators and repairs > > It took about a day to get it done but the cost was right and I kept all > my original parts and did not need to remove or ship the alternator. > > Paul > Legacy, Spruce Creek. > -- > For archives and unsub > http://mail.lancaironline.net:81/lists/lml/List.html > --20cf307d03b0bfd6ef04cc604e6b Content-Type: text/html; charset=ISO-8859-1 Content-Transfer-Encoding: quoted-printable
Paul:=A0
=A0
That was great info.=A0 Thank you fo= r taking the time to send it.
=A0
BTW, my coupling fail= ed at about 25 Hrs.=A0 A quote for a new coupling was close to $ 1000.=A0 F= ortunately,
it was under warrenty.=A0 Easy to install.
=A0
Reg= ards, Bill H.

On Wed, Oct 17, 2012 = at 5:43 AM, Paul Miller <pjdmiller@gmail.com> wrote:
My primary alternator is original equipment TCM 60A altern= ator with 660 hours. =A0It should have been inspected at 500 hours but I de= ferred that. =A0This note suggests that the diodes get a check during that = 500H inspection. =A0My secondary is a B&C 20A which was just replaced t= his year after 600+ hours after some windings failed. =A0I have had a lot o= f radio noise but nothing so bad as to take steps to fix it. =A0I had no id= ea that my primary was only partially functioning. =A0On this last trip fro= m Calgary to Texas and onto Florida, my primary was noted to have Zero outp= ut while taxiing for takeoff at Midland TX. =A0 I flew using the secondary = to charge both busses for the two legs into Florida. =A0After some testing = I ruled out the primary B&C regulator. =A0Today, I tested the field res= istance (15 ohms, acceptable range should be 12-100 ohms) which was perfect= . =A0The field is the rotor on this unit. =A0I decided to pull the housing = and check brushes which were found to be almost perfect (90% remaining afte= r 660 hours).

The stator was uniform in color and not shorted. =A0 It pulls out easily fo= r inspection. =A0 The body of the alternator was not removed from the engin= e making this test very fast and easy. =A0A quick check revealed all six di= odes (two each for the three phases) had failed. =A0Everything else was in = excellent condition. =A0This unit is similar to the standard Delco Remy 10S= i alternator and shares many parts. =A0 The diode replacement from Aircraft= Spruce is almost $200. =A0The new alternator is about $1400. =A0 A repair = with new rotor is about $500 including shipping and labor from a reputable = shop I spoke with.

The diode assembly was sourced at my local shop with a spare set of brushes= for $20 total. =A0These are 50A diodes (50A x 6 diodes) which is a robust = replacement satisfactory for even the 100A alternator. =A0I had to remove t= he B+ stud from the old diode assembly and press it into replacement diode = package. =A0The re-assembly took about 20 minutes and it fired up with 10A = charge on low engine idle. =A0This is much higher charge at low idle than I= can ever recall.

This means that I've been flying for some time with less than 6 diodes.= =A0 I probably was flying on one or two phases and getting some radio nois= e from the failed diodes. =A0 This may have been ongoing for years. =A0Test= ing diodes as part of a 500H inspection is simple to accomplish and guarant= ees some margin for partial failure. =A0 I have photos I can markup and add= for reference in a follow up email. =A0Here are the excellent contacts who= helped today:

1) TCM technical support 888.826.5465 Provided technical guidance and email= ed me the alternator service manual in PDF form (48p) without hesitation. 2) Bill at B&C Specialty, 316-283-8000, always helpful. =A0Provided tes= ting procedure for regulator and the following reference for repair.
3) Aircraft Systems, Rockford IL, 815-399-0225 TCM alternator repair specia= lists
4) Rupp Auto, New Smyrna Beach, bench testing, parts and expert on 10Si alt= ernators and repairs

It took about a day to get it done but the cost was right and I kept all my= original parts and did not need to remove or ship the alternator.

Paul
Legacy, Spruce Creek.
--
For archives and unsub http://mail.lancaironline.net:81/lists/lml/L= ist.html

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