 |
Matronics Email Lists
Web Forum Interface to the Matronics Email Lists
|
| View previous topic :: View next topic |
| Author |
Message |
FlyboyTR
Joined: 04 Nov 2006
Posts: 215
Location: Mobile, Alabama
|
 Posted: Mon Nov 27, 2006 3:38 pm Post subject: Continental IO-240: Alternator quit working, Coupling Failed |
 |
|
Hello,
Yesterday during flight my alternator quit charging. It is a Ford design with a Continental part # 633661 and using a Zeftronics R15VOL regulator (which is showing a green light on it's self diagnostic system). It is a direct drive on the rear of the engine. I am currently checking voltage/ohms, etc.
I noticed today that the alternator cooling fan does not turn when the crankshaft is rotated by hand or when the engine is running. Does this mean something mechanical has broken and my failure to charge is actually caused by the alternator not turning? I have read about a gear coupling on some larger engines…but can’t find any info regarding the alternator set up on the IO-240. Any info regarding my failed system would be greatly appreciated! Thanks in advance!
Travis 
| | - The Matronics AeroElectric-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?AeroElectric-List |
|
_________________
Travis Rayner
Mobile, AL
Skystar Vixen, N-789DF
Continental IO-240, Prince P-Tip Prop
ADI-II Autopilot
AnyWhereMap Navigation with weather
www.enotam.net (My Flying Info Website)
Last edited by FlyboyTR on Mon Oct 26, 2009 12:10 pm; edited 1 time in total |
|
| Back to top |
|
 |
mprather(at)spro.net
Guest
|
| Posted: Mon Nov 27, 2006 4:28 pm Post subject: Continental IO-240: Alternator quit working |
|
|
If the IO-240 is like the O200 (and other small Continentals with
alternator/generator drive) it might look like this:
http://www.bandc.biz/200gdesc.html
There's a forged/milled piece (?) a pair of rubber bushings and a stamped
sheet socket that together are used to transmit torque from the engine to
the alternator.
I think that in the O200 setup, the rubber bushings are kind of wear
items. They get squished flatter and flatter. The few airplanes I have
checked have a fair amount of slop between the gear and the alternator
rotor - caused by this squishing. I suppose that if the rubber
deteriorated far enough it might cause the drive fingers to fail...
Unfortunately, I think if that happens it will probably drop metal into
the accessory case. 
Aircraft spruce has the parts for the alternator drive:
http://www.aircraftspruce.com/catalog/eppages/generatorattparts.php
Again, I don't know if any of these parts are compatible with the IO-240..
The IO-240 might have more in common with the IO-360.
Matt-
| Quote: |
<flyboytr(at)bellsouth.net>
Hello,
Yesterday during flight my alternator quit charging. It is a Ford design
with a Continental part # 633661 and using a Zeftronics R15VOL regulator
(which is showing a green light on it's self diagnostic system). It is a
direct drive on the rear of the engine. I am currently checking
voltage/ohms, etc.
I noticed today that the alternator cooling fan does not turn when the
crankshaft is rotated by hand or when the engine is running. Does this
mean something mechanical has broken and my failure to charge is actually
caused by the alternator not turning? I have read about a gear coupling
on some larger engines…but can’t find any info regarding the
alternator set up on the IO-240. Any info regarding my failed system
would be greatly appreciated! Thanks in advance!
Travis
--------
Travis Rayner
Mobile, AL
Skystar Vixen
N-789DF
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p=77430#77430
|
| | - The Matronics AeroElectric-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?AeroElectric-List |
|
|
|
| Back to top |
|
|
bakerocb
Joined: 15 Jan 2006
Posts: 727
Location: FAIRFAX VA
|
| Posted: Tue Nov 28, 2006 5:12 am Post subject: Continental IO-240: Alternator quit working |
|
|
11/28/2006
Hello Travis, You most probably have a failure of the elastomeric coupling
drive of the alternator.
TCM Service Bulletin SB95-3B describes this coupling in detail and I have
attached a copy of that SB to this email. If you can not see it please let
me know and we'll work on another way to get it to you.
Buying a replacement coupling from TCM is very expensive. There is an outfit
in Texas that rebuilds them and will sell you one for a cheaper price. Try
Drake Air Inc at 800-542-6899. They may also know it as ATA Number DAP-1016.
http://www.drakeair.com/details.asp?id=635796
According to the IO-240 part manual the IO-240 uses the one piece P/N 635796
one piece coupling. I don't see that coupling as being available from
Aircraft Spruce, but you could check with them.
Please let me know if I can be of further help.
OC -- The best investment we will ever make is in gathering knowledge.
Time: 03:40:14 PM PST US
Subject: Continental IO-240: Alternator quit working
From: "FlyboyTR" <flyboytr(at)bellsouth.net>
Hello,
Yesterday during flight my alternator quit charging. It is a Ford design
with
a Continental part # 633661 and using a Zeftronics R15VOL regulator (which
is
showing a green light on it's self diagnostic system). It is a direct drive
on
the rear of the engine. I am currently checking voltage/ohms, etc.
I noticed today that the alternator cooling fan does not turn when the
crankshaft
is rotated by hand or when the engine is running. Does this mean something
mechanical has broken and my failure to charge is actually caused by the
alternator
not turning? I have read about a gear coupling on some larger enginesbut
cant find any info regarding the alternator set up on the IO-240. Any info
regarding my failed system would be greatly appreciated! Thanks in
advance!
Travis
--------
Travis Rayner
Mobile, AL
Skystar Vixen
N-789DF
| | - The Matronics AeroElectric-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?AeroElectric-List |
|
| Description: |
|
Download |
| Filename: |
SB95-3B.pdf |
| Filesize: |
46.72 KB |
| Downloaded: |
1355 Time(s) |
|
|
| Back to top |
|
|
FlyboyTR
Joined: 04 Nov 2006
Posts: 215
Location: Mobile, Alabama
|
| Posted: Tue Nov 28, 2006 5:46 am Post subject: Re: Continental IO-240: Alternator quit working |
|
|
Thanks for the information! I have sent Drake Air an email regarding the drive coupling. In order to remove the alternator I have to pull the engine! ...nothing is ever easy! Again, thanks to all for the input and support!
Travis
| | - The Matronics AeroElectric-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?AeroElectric-List |
|
_________________
Travis Rayner
Mobile, AL
Skystar Vixen, N-789DF
Continental IO-240, Prince P-Tip Prop
ADI-II Autopilot
AnyWhereMap Navigation with weather
www.enotam.net (My Flying Info Website) |
|
| Back to top |
|
|
oldbob(at)BeechOwners.com
Guest
|
| Posted: Tue Nov 28, 2006 6:47 am Post subject: Continental IO-240: Alternator quit working |
|
|
Good Morning OC,
May I add a comment?
If someone does have a slipping Elastomeric coupling,
don't let it be discarded.
They can be refurbished for about one third the cost
of a new coupling.
Happy Skies,
Old Bob
AKA
Bob Siegfried
Ancient Aviator
Stearman N3977A
Brookeridge Air Park LL22
Downers Grove, IL 60516
630 985-8503
--- bakerocb(at)cox.net wrote:
| Quote: | 11/28/2006
Hello Travis, You most probably have a failure of
the elastomeric coupling
drive of the alternator.
TCM Service Bulletin SB95-3B describes this coupling
in detail and I have
attached a copy of that SB to this email. If you can
not see it please let
me know and we'll work on another way to get it to
you.
Buying a replacement coupling from TCM is very
expensive. There is an outfit
in Texas that rebuilds them and will sell you one
for a cheaper price. Try
Drake Air Inc at 800-542-6899. They may also know it
as ATA Number DAP-1016.
http://www.drakeair.com/details.asp?id=635796
According to the IO-240 part manual the IO-240 uses
the one piece P/N 635796
one piece coupling. I don't see that coupling as
being available from
Aircraft Spruce, but you could check with them.
Please let me know if I can be of further help.
OC -- The best investment we will ever make is in
gathering knowledge.
Time: 03:40:14 PM PST US
Subject: Continental IO-240:
Alternator quit working
From: "FlyboyTR" <flyboytr(at)bellsouth.net>
Hello,
Yesterday during flight my alternator quit charging.
It is a Ford design
with
a Continental part # 633661 and using a Zeftronics
R15VOL regulator (which
is
showing a green light on it's self diagnostic
system). It is a direct drive
on
the rear of the engine. I am currently checking
voltage/ohms, etc.
I noticed today that the alternator cooling fan does
not turn when the
crankshaft
is rotated by hand or when the engine is running.
Does this mean something
mechanical has broken and my failure to charge is
actually caused by the
alternator
not turning? I have read about a gear coupling on
some larger enginesbut
cant find any info regarding the alternator set up
on the IO-240. Any info
regarding my failed system would be greatly
appreciated! Thanks in
advance!
Travis
--------
Travis Rayner
Mobile, AL
Skystar Vixen
N-789DF
|
| | - The Matronics AeroElectric-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?AeroElectric-List |
|
|
|
| Back to top |
|
|
FlyboyTR
Joined: 04 Nov 2006
Posts: 215
Location: Mobile, Alabama
|
| Posted: Wed Nov 29, 2006 3:38 pm Post subject: Re: Continental IO-240: Alternator quit working |
|
|
I pulled the engine today for access to the alternator. There was one nut (top) that was almost impossible to remove (ended up removing the starter for easier access) on the alternator. The drive gear on the end of the alternator shaft rotates freely! I have emailed Drake Air (also left them a voice mail...have heard back from them) regarding their rebuilt units. This does not look like a field serviceable part as shown in the Aircraft spruce book (doesn't look the same)! I would welcome any contact names for parts suppliers/rebuilders that would carry this part. I also realized today that I need to replace the motor mount bushings!
Thanks again!
Travis
| | - The Matronics AeroElectric-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?AeroElectric-List |
|
_________________
Travis Rayner
Mobile, AL
Skystar Vixen, N-789DF
Continental IO-240, Prince P-Tip Prop
ADI-II Autopilot
AnyWhereMap Navigation with weather
www.enotam.net (My Flying Info Website) |
|
| Back to top |
|
|
FlyboyTR
Joined: 04 Nov 2006
Posts: 215
Location: Mobile, Alabama
|
| Posted: Sat Dec 02, 2006 6:43 am Post subject: Re: Continental IO-240: Alternator quit working |
|
|
I wanted to bring closure to this issue. Please accept my sincere appreciation to all those that provided a wealth of information. The elastomeric puck was the failed part. I sent Drake Air my old part so it could be rebuilt. They charge $450 for this service. Aircraft Spruce does NOT carry this part. They carry the rebuild parts for a different drive coupling. I have attached some pictures showing the coupling and the engine removal. Again, Thanks to everyone for your help and support.
Travis
| | - The Matronics AeroElectric-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?AeroElectric-List |
|
| Description: |
|
| Filesize: |
456.05 KB |
| Viewed: |
1133 Time(s) |
|
| Description: |
|
| Filesize: |
443.62 KB |
| Viewed: |
1080 Time(s) |
|
| Description: |
| To purchase new, $1,600.00 from TCM! DO NOT throw your old core away! |
|
| Filesize: |
389.6 KB |
| Viewed: |
1146 Time(s) |
|
| Description: |
| Elastomeric puck: Was not making much contact! |
|
| Filesize: |
424.07 KB |
| Viewed: |
1115 Time(s) |
|
| Description: |
| Coupling attached to alternator |
|
| Filesize: |
378.03 KB |
| Viewed: |
1073 Time(s) |
|
| Description: |
|
| Filesize: |
377.18 KB |
| Viewed: |
1124 Time(s) |
|
_________________
Travis Rayner
Mobile, AL
Skystar Vixen, N-789DF
Continental IO-240, Prince P-Tip Prop
ADI-II Autopilot
AnyWhereMap Navigation with weather
www.enotam.net (My Flying Info Website) |
|
| Back to top |
|
|
FlyboyTR
Joined: 04 Nov 2006
Posts: 215
Location: Mobile, Alabama
|
| Posted: Mon Oct 26, 2009 12:17 pm Post subject: Re: Continental IO-240: Alternator quit working, Coupling Fa |
|
|
The past 254 hours have been great...until yesterday. My alternator coupling failed...AGAIN! I had purchased a rebuilt unit from Drake Air (as noted above in this thread). $450 versus $1,600 from TCM for a new one.
Is there any reason this part should fail so soon? Oil, hours, temps, alternator load, how the load is applied, etc?
I emailed Drake Air this morning and was inquiring as to why their part failed...prematurely...in my opinion!
I have to pull my engine to remove the alternator. ...insult to injury! 
Again...I welcome input from the forum!
Travis
| | - The Matronics AeroElectric-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?AeroElectric-List |
|
_________________
Travis Rayner
Mobile, AL
Skystar Vixen, N-789DF
Continental IO-240, Prince P-Tip Prop
ADI-II Autopilot
AnyWhereMap Navigation with weather
www.enotam.net (My Flying Info Website) |
|
| Back to top |
|
|
|
|
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum
You cannot attach files in this forum
You can download files in this forum
|
Powered by phpBB © 2001, 2005 phpBB Group
|
Get Email Distribution Too!
FAQ
Search
Memberlist
Usergroups
Register
Profile
Log in to check your private messages
Log in
