---------------------------------------------------------- JabiruEngine-List Digest Archive --- Total Messages Posted Thu 10/30/08: 8 ---------------------------------------------------------- Today's Message Index: ---------------------- 1. 02:49 AM - Found it at last-Coil feed wires not crimped on new alternator coil. (James, Clive R) 2. 04:07 AM - Re: Found it at last-Coil feed wires not crimped on new alternator coil. (Lynn Matteson) 3. 04:11 AM - Re: Found it at last-Coil feed wires not crimped on new alternator coil. (Lynn Matteson) 4. 07:46 AM - Re: Found it at last-Coil feed wires not crimped on new alternator coil. (James, Clive R) 5. 11:54 AM - Re: Found it at last-Coil feed wires not crimped on new alternator coil. (japhillipsga@aol.com) 6. 01:08 PM - Re: Found it at last-Coil feed wires not crimped on new alternator coil. (James, Clive R) 7. 02:15 PM - Re: Found it at last-Coil feed wires not crimped on new alternator coil. (THOMAS SMALL) 8. 03:25 PM - Re: Found it at last-Coil feed wires not crimped on new alternator coil. (James, Clive R) ________________________________ Message 1 _____________________________________ Time: 02:49:54 AM PST US Subject: JabiruEngine-List: Found it at last-Coil feed wires not crimped on new alternator coil. From: "James, Clive R" <> 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 ________________________________ Message 2 _____________________________________ Time: 04:07:01 AM PST US From: Lynn Matteson Subject: Re: JabiruEngine-List: Found it at last-Coil feed wires not crimped on new alternator coil. 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: > 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 > > ________________________________ Message 3 _____________________________________ Time: 04:11:23 AM PST US From: Lynn Matteson Subject: Re: JabiruEngine-List: Found it at last-Coil feed wires not crimped on new alternator coil. 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: > 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 > > ________________________________ Message 4 _____________________________________ Time: 07:46:28 AM PST US Subject: RE: JabiruEngine-List: Found it at last-Coil feed wires not crimped on new alternator coil. From: "James, Clive R" 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 -----Original Message----- From: owner-jabiruengine-list-server@matronics.com [mailto:owner-jabiruengine-list-server@matronics.com] On Behalf Of Lynn Matteson Sent: 30 October 2008 11:11 Subject: Re: JabiruEngine-List: Found it at last-Coil feed wires not crimped on new alternator coil. --> 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: > 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 > > ________________________________ Message 5 _____________________________________ Time: 11:54:40 AM PST US Subject: Re: JabiruEngine-List: Found it at last-Coil feed wires not crimped on new alternator coil. From: japhillipsga@aol.com Clive, great info and photos. Did this manifest itself in engine performance one way or the other or only in charging the battery ? What time frame did you buy the 3300? Thanks, Bill of Georgia -----Original Message----- From: James, Clive R Sent: Thu, 30 Oct 2008 5:49 am Subject: JabiruEngine-List: Found it at last-Coil feed wires not crimped on new alternator coil. <> 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 [Image Removed] ________________________________ Message 6 _____________________________________ Time: 01:08:49 PM PST US Subject: RE: JabiruEngine-List: Found it at last-Coil feed wires not crimped on new alternator coil. From: "James, Clive R" Hi Bill. only effect was battery volts dropping thought not conclusively. Charge light didn't come on for instance. Plane was built in 2004. New coils (with dodgy crimps) were fitted in 2006 or 7. Regards, Clive ________________________________ From: owner-jabiruengine-list-server@matronics.com [mailto:owner-jabiruengine-list-server@matronics.com] On Behalf Of japhillipsga@aol.com Sent: 30 October 2008 18:54 Subject: Re: JabiruEngine-List: Found it at last-Coil feed wires not crimped on new alternator coil. Clive, great info and photos. Did this manifest itself in engine performance one way or the other or only in charging the battery ? What time frame did you buy the 3300? Thanks, Bill of Georgia -----Original Message----- From: James, Clive R Sent: Thu, 30 Oct 2008 5:49 am Subject: JabiruEngine-List: Found it at last-Coil feed wires not crimped on new alternator coil. <> 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 [Image Removed] AOL News. ________________________________ Message 7 _____________________________________ Time: 02:15:50 PM PST US From: "THOMAS SMALL" Subject: Re: JabiruEngine-List: Found it at last-Coil feed wires not crimped on new alternator coil. Clive, Are you speaking ignition coils (two of them, either black or dark gray in color) or the "coils" in the rotating alternator??? A mismatch in terms here might tend to confuse those of us who speak American English. Connectors in ignition coils should have no impact on charging. CAVU jeff New coils (with dodgy crimps) were fitted in 2006 or 7. ________________________________ Message 8 _____________________________________ Time: 03:25:11 PM PST US Subject: RE: JabiruEngine-List: Found it at last-Coil feed wires not crimped on new alternator coil. From: "James, Clive R" Sorry, alternator 'stator' coils. CAVU? CJ ________________________________ From: owner-jabiruengine-list-server@matronics.com [mailto:owner-jabiruengine-list-server@matronics.com] On Behalf Of THOMAS SMALL Sent: 30 October 2008 21:11 Subject: Re: JabiruEngine-List: Found it at last-Coil feed wires not crimped on new alternator coil. Clive, Are you speaking ignition coils (two of them, either black or dark gray in color) or the "coils" in the rotating alternator??? A mismatch in terms here might tend to confuse those of us who speak American English. Connectors in ignition coils should have no impact on charging. CAVU jeff New coils (with dodgy crimps) were fitted in 2006 or 7. ------------------------------------------------------------------------------------- Other Matronics Email List Services ------------------------------------------------------------------------------------- Post A New Message jabiruengine-list@matronics.com UN/SUBSCRIBE http://www.matronics.com/subscription List FAQ http://www.matronics.com/FAQ/JabiruEngine-List.htm Web Forum Interface To Lists http://forums.matronics.com Matronics List Wiki http://wiki.matronics.com Full Archive Search Engine http://www.matronics.com/search 7-Day List Browse http://www.matronics.com/browse/jabiruengine-list Browse Digests http://www.matronics.com/digest/jabiruengine-list Browse Other Lists http://www.matronics.com/browse Live Online Chat! http://www.matronics.com/chat Archive Downloading http://www.matronics.com/archives Photo Share http://www.matronics.com/photoshare Other Email Lists http://www.matronics.com/emaillists Contributions http://www.matronics.com/contribution ------------------------------------------------------------------------------------- These Email List Services are sponsored solely by Matronics and through the generous Contributions of its members.