Posted by Bob on April 19, 2017 at 08:45:34 from (64.255.159.192):
In Reply to: alternator issues posted by gary in neb. on April 19, 2017 at 06:33:27:
Automotive alternators are inherently self-current limiting and should be able to charge at max Amps all day long if there's adequate cooling air flow, so they shouldn't be dying from being loaded.
Run a new 8 or 10 GA wire from the output stud to to main starter solenoid stud where the (+) battery cable connects to eliminate the possibility there's a high resistance connection or an occasional "open" in the factory wiring. Alternators do not like those sorts of things.
You can leave the factory wiring in place, in parallel, so accessories are supplied with power as they were before.
While you're at it, run a "voltage sense" wire from the #2 alternator's terminal to the same stud at the starter solenoid.
Be SURE there's a resistor, an "idiot light" or a diode in the wiring from the ignition switch to the alternator's #1 "excite" terminal.
If wired WITHOUT any of those, the alternator will try to charge through that path, loading the diode trio and internal wiring in the voltage regulator.
That being said, a customer's GREEN 4430 has gone through two replacement 12SI alternators, we just installed the third, in less than 50 hours.
They have been lifetime warranty units from an autoparts chain who shall remain nameless (but was suggested by another poster to this thread).
The first two had stators that looked like they'd been just pulled out of a core and re-used without oven a good cleaning and a new coat of insulating varnish.
The last one we just installed appears to be all new except for the bead-blasted reused case, reman in china. We'll see how long this one lasts!
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