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Found it at last-Coil feed wires not crimped on new alternat

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Clive J

Joined: 03 Nov 2007
Posts: 340
Location: UK

Posted: Thu Oct 30, 2008 1:49 am Post subject: Found it at last-Coil feed wires not crimped on new alternat

<<Crimps.JPG>> I've been chasing a charging problem on an aircraft in my hangar for a few years. J430 3300 Jabiru. Some time ago the agent changed the alternator coils for new ones whilst doing some elimination fault finding and the problem seemed to be cured for a year or so though it was never clear what the problem was.   

However a few flights recently have shown some intermittent charging and on the last flight the radio packed up as the voltage was so low. The battery situation wasn't clear as it had been swapped many times for a spare so we started with charging the battery fully on the ground. Still no charge when running and as I began to start with measuring the AC from the coil I noticed some scorching in the AC lead connectors, see attached. Examining the scorched one it came off in my hand. I gentle pull on it's partner and this too also came off. The ends on the wires were stripped and 'tinned' but it is clear from examining the crimps they have never been either soldered or crimped to grip on the conductor.  

Suggest you give your AC connections a good pull next time you have the cowlings off in case yours have the same problem which may manifest itself at an awkward moment. May also be worth sliding the insulation back and examining the crimp appearance or chopping them off and putting better ones on.  

Regards, Clive

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Lynn Matteson

Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

Posted: Thu Oct 30, 2008 3:07 am Post subject: Found it at last-Coil feed wires not crimped on new alternat

Thanks, Clive....I've had an intermittent high voltage report (from  

my EIS) and by the time I can glance over to see what it was, it  

corrects itself. I will look into this.



Lynn Matteson

Kitfox IV Speedster

Jabiru 2200, 579.1hrs

Sensenich 62x46

flying again (17 hrs) after rebuild, and new Electroair direct-fire  

ignition system



On Oct 30, 2008, at 5:49 AM, James, Clive R wrote:



 	  Quote: 	
		   I've been chasing a charging problem on an aircraft in my hangar  

 for a few years. J430 3300 Jabiru. Some time ago the agent changed  

 the alternator coils for new ones whilst doing some elimination  

 fault finding and the problem seemed to be cured for a year or so  

 though it was never clear what the problem was.



 However a few flights recently have shown some intermittent  

 charging and on the last flight the radio packed up as the voltage  

 was so low. The battery situation wasn't clear as it had been  

 swapped many times for a spare so we started with charging the  

 battery fully on the ground. Still no charge when running and as I  

 began to start with measuring the AC from the coil I noticed some  

 scorching in the AC lead connectors, see attached. Examining the  

 scorched one it came off in my hand. I gentle pull on it's partner  

 and this too also came off. The ends on the wires were stripped and  

 'tinned' but it is clear from examining the crimps they have never  

 been either soldered or crimped to grip on the conductor.



 Suggest you give your AC connections a good pull next time you have  

 the cowlings off in case yours have the same problem which may  

 manifest itself at an awkward moment. May also be worth sliding the  

 insulation back and examining the crimp appearance or chopping them  

 off and putting better ones on.



 Regards, Clive

- The Matronics JabiruEngine-List Email Forum -

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_________________
Lynn
Kitfox IV-Jabiru 2200
N369LM

Lynn Matteson

Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

Posted: Thu Oct 30, 2008 3:11 am Post subject: Found it at last-Coil feed wires not crimped on new alternat

I just thought of something, Clive....when I first got my engine, Ben  

Krotje told me to cut the connectors off from the alternator leads  

and crimp on the normal 1/4" wide terminals. I had forgotten about  

this (it was 3 years ago), and I was just wondering if you still had  

the original, narrow, terminals on your alternator leads when you  

noticed the problem?



Lynn Matteson

Kitfox IV Speedster

Jabiru 2200, 579.1hrs

Sensenich 62x46

flying again (17 hrs) after rebuild, and new Electroair direct-fire  

ignition system

On Oct 30, 2008, at 5:49 AM, James, Clive R wrote:



 	  Quote: 	
		   I've been chasing a charging problem on an aircraft in my hangar  

 for a few years. J430 3300 Jabiru. Some time ago the agent changed  

 the alternator coils for new ones whilst doing some elimination  

 fault finding and the problem seemed to be cured for a year or so  

 though it was never clear what the problem was.



 However a few flights recently have shown some intermittent  

 charging and on the last flight the radio packed up as the voltage  

 was so low. The battery situation wasn't clear as it had been  

 swapped many times for a spare so we started with charging the  

 battery fully on the ground. Still no charge when running and as I  

 began to start with measuring the AC from the coil I noticed some  

 scorching in the AC lead connectors, see attached. Examining the  

 scorched one it came off in my hand. I gentle pull on it's partner  

 and this too also came off. The ends on the wires were stripped and  

 'tinned' but it is clear from examining the crimps they have never  

 been either soldered or crimped to grip on the conductor.



 Suggest you give your AC connections a good pull next time you have  

 the cowlings off in case yours have the same problem which may  

 manifest itself at an awkward moment. May also be worth sliding the  

 insulation back and examining the crimp appearance or chopping them  

 off and putting better ones on.



 Regards, Clive

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_________________
Lynn
Kitfox IV-Jabiru 2200
N369LM

Clive J

Joined: 03 Nov 2007
Posts: 340
Location: UK

Posted: Thu Oct 30, 2008 6:46 am Post subject: Found it at last-Coil feed wires not crimped on new alternat

Yes these were the originals. You have it covered already and I suspect

Ben came across the issue many years ago....



The first Jab engine I got I looked the connectors over and they looked

good so I just used the 1/4 blades in them and heat shrinked over the

lot. They are still on the plane and it's done 1000 hrs with good volts

throughout. It was likely that these badly fitted ones could have lasted

as well. I'm not sure if my Esqual engine has them changed or not, it's

an age thing.....



Regards, Clive



--

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