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ScooterF15
Joined: 19 Jun 2006
Posts: 136
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 Posted: Tue May 31, 2011 4:32 pm Post subject: Failed Alternator |
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Hi RV-10 Group,
My alternator failed after around 200 hours of flight (over 5 years) and I learned some things that may be worth sharing. I am using the 60 amp alternator that came with the Van’s Firewall Forward kit in 2005 (not sure what they are shipping now). See attached photo of the alternator. I have learned that it came from a Suzuki Samuri (part #14684), or a Geo Tracker, or a Toyota forklift, although I’m not sure if they did any mods to it before including it in the kit. According to the alternator repair shop I took it to, I don’t think so.
Upon landing last week, I noticed that my voltage was ~11.3 V. I tried a quick run-up and that didn’t bring up the voltage. I tested my batteries the next day and they were both quite discharged. I downloaded my engine data and saw that the alternator voltage had gone down the day before the flight during an engine run. It was still putting out current, so when I looked at that during my run-up/flight it didn’t catch my eye. However, the voltage was too low to charge the batteries and they continued to discharge throughout the flight. First lesson learned – I need to set a higher lower-limit for low voltage on my engine monitor.
I took it to a shop and the tech immediately pointed out that one of the three phases was burned out . He saws this easily by the white globs of melted plastic on every third coil (see other photo). Upon disassembly this was caused by a mechanical failure of one of the phase leads (see picture), the other two were still making power. This failure was either due to the way the stator was installed during manufacture, or excessive vibration (again, I only have ~200 hours on the plane). I just had my prop balanced, maybe I should have done that sooner.
That’s it. Hope that helps someone.
-Jim
N312JE
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cjay
Joined: 15 Dec 2007
Posts: 53
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| Posted: Tue May 31, 2011 4:56 pm Post subject: Re: Failed Alternator |
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Jim,
Can't really tell from the picture, but it doesn't look like the plane power alternator? I had insufficient voltage with my alternator from the start, it was between 12.5 to 13.5 ,always causing me to conserve amps in flight. Plane power kept directing me to do diagnostic tests, saying it was usually a short or bad wiring somewhere else. Finally they took it back, checked it out, said nothing was wrong, but replaced a couple things (not sure what) and its been running great ever sense.
cjay
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flysrv10(at)gmail.com
Guest
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| Posted: Tue May 31, 2011 5:02 pm Post subject: Failed Alternator |
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Mine failed at exactly 200 hrs. Van replaced it without charge. Not sure if I have a different one now but I have accumulated 360 hr on the replacement.
Rob Kermanj
Sent from my iPad
On May 31, 2011, at 8:30 PM, "James McGrew" <jsmcgrew(at)alum.mit.edu (jsmcgrew(at)alum.mit.edu)> wrote:
| Quote: |
Hi RV-10 Group,
My alternator failed after around 200 hours of flight (over 5 years) and I learned some things that may be worth sharing. I am using the 60 amp alternator that came with the Van’s Firewall Forward kit in 2005 (not sure what they are shipping now). See attached photo of the alternator. I have learned that it came from a Suzuki Samuri (part #14684), or a Geo Tracker, or a Toyota forklift, although I’m not sure if they did any mods to it before including it in the kit. According to the alternator repair shop I took it to, I don’t think so.
Upon landing last week, I noticed that my voltage was ~11.3 V. I tried a quick run-up and that didn’t bring up the voltage. I tested my batteries the next day and they were both quite discharged. I downloaded my engine data and saw that the alternator voltage had gone down the day before the flight during an engine run. It was still putting out current, so when I looked at that during my run-up/flight it didn’t catch my eye. However, the voltage was too low to charge the batteries and they continued to discharge throughout the flight. First lesson learned – I need to set a higher lower-limit for low voltage on my engine monitor.
I took it to a shop and the tech immediately pointed out that one of the three phases was burned out . He saws this easily by the white globs of melted plastic on every third coil (see other photo). Upon disassembly this was caused by a mechanical failure of one of the phase leads (see picture), the other two were still making power. This failure was either due to the way the stator was installed during manufacture, or excessive vibration (again, I only have ~200 hours on the plane). I just had my prop balanced, maybe I should have done that sooner.
That’s it. Hope that helps someone.
-Jim
N312JE
<Suzuki_Samuri_14684.jpg>
<Failed_Indication.JPG>
<Broken_stator.JPG>
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Albert Gardner
Joined: 10 Jan 2006
Posts: 455
Location: Yuma, AZ
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| Posted: Tue May 31, 2011 5:34 pm Post subject: Failed Alternator |
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My Vans supplied 60 A alternator failed at about 150 hours. The replacement was an Nippondenso Model 36-14684N from an auto parts store and seems to be working fine at 550 hrs. I get the impression that a suitable alternator may be found under several manufacturer/part no. combinations.
Albert Gardner
N991RV
Yuma, AZ
[quote][b]
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_________________
RV-9A N872RV
RV-10 N991RV |
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ScooterF15
Joined: 19 Jun 2006
Posts: 136
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| Posted: Wed Jun 01, 2011 4:09 am Post subject: Failed Alternator |
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Cjay,
I believe I purchased mine before Van's started selling Plane Power
alternators.
-Jim
--
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