What Causes Alternator Wire To Melt

Grounded alternator casing appropriately. The ELD is a three wire unit mounted in the fusebox with a primary voltage lead, a primary ground, and a load output lead which is used by the PCM. CORRECT WIRE SIZE IS CRITICAL: It is very important to use the correct wire size to connect the alternator to the battery. That's what I'd like to do, but it seems that this alternator is uncommon (it took the mechanic a couple of days to get one, because all the parts stores had the "FEN" alternator in stock, but the "LEF" alternator, which he said I needed, was special order); and I don't know how to identify the correct alternator and harness like say, in a junkyard; and I especially don't know what to ask for. An overheated electrical connection has but one cause, resistance to electron flow. You should be able to get all those tools and the stud at a hardware store for under $20. A drained battery is often the Alternator with shorted diode stack. Any sign that the terminal had arced against the hood above the battery. So, you can see, based on the table, that a wire of AWG 4 can carry 59. Alternator Whine in Car Audio. If the battery is dead, it does not mean this is the only problem you now face. Disconnecting or not having the coax cable ground. Although it has nippodenso markings all over. The bearings on which the alternator rotates can also be at fault and hinder the alternator from providing an optimal performance. I have a problem with my alternator heating up due to it working at all the time 100% capacity. As noted above, discharged batteries will cause other problems. • Never use a Mega-Ohm tester on an alternator. Replied by dosmastr on topic Engine ground wire melted??? As you can see, all that wire is, is a ground for the engine, it's point to point, engine to the frame - nothing else. The alternators can wear prematurely. Car Audio Noise. There must be too much amperage going through the wire. But I can't blame John, the wire that is feeding the alternator power to charge is the factory Monte harness. Adding this bypass charge wire will significantly reduce the chance of melt-ing the firewall connections, but it will also cause the ammeter to stop working correctly. A short is when a positive wire goes directly to ground without a load in the circuit. Since most late-model import alternators are ­internally regulated, a failure of the regulator means the alternator must also be replaced. 99 Toyota camery : the wire between new alternator and battery gets hot, melted casing, and the fuse didn't blow. On mine, it's tied to the charging wire, which is run thru my flip switch. DIAGNOSE – BURNING ODOR COMING FROM UNDER THE HOOD. If you smelled burning you might want to look at the wiring going to the alternator, sometimes if there is a bad connection anywhere there it gets realllllyy hot and melts the wiring. 3 million vehicles worldwide to fix malfunctioning alternators that can cause engines to stall or a wiring problem that can make air bags deploy. Ignoring the load resistance and then saying that increasing resistance will not cause the wires to heat up and melt is irresponsible and unsafe. My car has 60000 miles. The changing magnetic field also causes some losses. Fans have been replaced by a show and so has cooling fan module. I've had wire melt on headers at idle when I accidentally allowed them to touch the headers for a few minutes. Wiki User 09/18/2010. Connected to the B terminal of the alternator is a fairly heavy wire that runs straight to the battery. Many auto parts stores, and Harbor Freight Tools, sell small battery post cleaner tools. Other causes for a car failing to start are a bad starter or relay. A nice variety of birds love eating this no melt peanut butter suet. If you need to, use some copper washers underneath the ring terminal to help it seat properly, the factory connector is small and tabbed so that it will fit inside the plastic insulator. I replace it. In some cases even a new stock size belt will slip. For more Coconuts stories, you can download our app, sign up for our newsletters, or follow us on Facebook, Twitter, and Instagram. Basic braking isn’t affected. Some of those beasts had a huge braided wire which ran from the starter motor bolt right to the chassis frame. That could cause engine stalling and compromise antilock brakes and electronic stability control. Good thing: Kickin' audio system with megawatt amps, big subs, zillions of speakers, crossovers, and enough wire to hook up your average city. turn switch, electric fan, horn, battery feed, alternator and alternator exciter wire, coil, and air conditioning. I peeled back wires connected to the post and separated each one a good few inches. Looks like 10 gauge wire. Alternator ground wire insulation melting. My car has an automatic transmission. The green wire that comes out of the regulator that goes back to the second field had broken strands at the connecter and broke off after a couple of wiggles. if you have a salvage yard near you go there and find a durango with the same engine as your cut those wires of and your and then rewire it look at the dodge rams as well. There is also an issue with respect to battery monitoring systems (BMS), in that drawing the battery voltage down past a preset point, can cause the MIL to illuminate, and a code being written. with your question. Alternator Removal and Installation Instructions Removal Make sure that the rest of your charging system is in good working order. ” This means that salt helps in lowering the freezing point and, consequently, the melting point of water (the main component of snow and ice). 4 volts is fine. So this is telling me that no wires were crossed, etc. Turns that short together will also cause problems. Depending on the fault, a current of 50 A might flow for a few seconds, enough to start a fire or cause a serious burn. Autozone would not replace the alternator (their brand with supposed lifetime warranty) because it was not an alternator problem to begin with. By doubling the wires the current is less for each wire prolonging the the life of the circuit. Why? This can be caused by a few different things. Read more about a serpentine belt. The hot wire scent can be caused by an overheated alternator, one pushing too much power through the rotor and stator. Looks like 10 gauge wire. 2) Now turn on the headlights if the voltage drops below 12. 1st, ensure the engine on the working vehicle. A loose wire connection will cause high resistance which will cause heat and eventually cause the wire insulation to melt and when the bare wire touches cabinet ground it will pop and spark. Make sure you have the proper size ring terminal, use a wire brush to clean the alternator stud and nut. Below are five common causes for an alternator to go bad. Depending upon the maximum output of the alternator, use the following chart as a minimum wire size guide. This message. Causes of Alternator Not Charging the Battery. The first item to check would be the alternator. Can anyone help me with the problem. The alternator to fuse box wire is 4 gauge; so, this short fuse box to battery wire is the weak link - not any more. That could result in wires melting, but if you have connections that are getting real hot, that is due to resistance. The first thing to check in any no charge condition is to make sure the battery negative cable, which should be bolted to the engine block or head, is in good condition, the ends are free of rust and corrosion, and that it is. DIAGNOSE – BURNING ODOR COMING FROM UNDER THE HOOD. This will do the same thing as. Without an alternator, the engine in your car would have no spark, your headlights no light, and your heater no way to keep you comfortable in the winter. Your local Pep Boys offers services designed to fix or replace the electrical part in question, from your car battery to your alternator, trust the experts at Pep Boys to provide the solution you need. Aluminum is in use by the utility companies for the transmission of electricity since the early 1900’s. Without a fuse or some kind of overload protection the amperage running thru the wire can also melt the insulation and cause a fire. Do the stator tests in the manual and see if that is the problem. Small tie wraps. Root cause determined to be corrosion on alternator power supply cable that created heat enough to melt plastic (~450F) and burn the protective cover off the alternator supply wire back 2 inches. Re: Dead battery, Jeep quits, new alternator. Common Scenarios. Occasionally, a symptom of this issue might be brighter lights, as the alternator produces more energy to overcome the resistance in a bad wire or a. The wiring that is of concern involves the circuit wiring to your outlets and light switches, and to appliances that use 115 volt current, such as the furnace and washing machine. I checked it by turning the key on(not starting) and taking the blue wire loose and when I read it with the meter it only read. It contains a starter winding. Without an alternator, the engine in your car would have no spark, your headlights no light, and your heater no way to keep you comfortable in the winter. Replied by no_common_sense on topic B+ terminal cover melted. Car Fires: Causes, Prevention and What to Do. Place cookies on a wire rack over waxed paper. In removing the alternator the location of the ground wire was melted off of the back, tracing the wire back a little showed the melted other side. Don't test an alternator by disconnecting the negative battery cable. Wire is probably. The orange wire was stiff. Overheated alternator output wire - check the red wire on the alternator for melted or blistering insulation. If this problem DID NOT occur before the New Alternator installationthen one must assume a bad alt. The good news is the new alternator came online when I started the. But more importantly, you may experience difficulty in starting and driving your car, preventing it to fully operate. Evening all. The crimper tool crimps 14 to 0 AWG copper and aluminum wires using steel crimping dies. id say disconnect the cable from the alternator and see if the short goes away. In most modern systems, the electrical current passing through the filament of the warning light is what energizes a circuit in the alternator to start charging. The stator is made of copper wires and powers the alternator when the magnet on the rotor spins past it at high speed. The output voltage of alternator must be at a level that is capable of compensating for battery draws from electrical components including the starter, lighting and various other accessories. 3 million vehicles worldwide to fix malfunctioning alternators that can cause engines to stall or a wiring problem that can make air bags deploy. The diodes in an automobile's alternator serve the same function as a one-way check valve does in a hydraulic system. The alternator wire gets very hot and it melted the top of my battery. A fusible link is a "narrow spot" in your wire, a portion of higher resistance that will overheat, melt and break before the rest of your wiring does. Ignition switch and starter motor failure present similar symptoms. only if a big short happened to the battery and melted the cells in to a short inside the batt Related Questions Asked in Alternators. The problem that you might think as a single problem can often be the root cause of many other car problems. So I installed a 3g alternator with the proper wiring in May 2012. This happened to me on 2002 Beetle a week ago. edu 2,3 and 4 wire coil versions are different in. this is done with a meter attachment that clamps around the wire output of the alternator. And a dual terminal connector. Among the various common charging system problems you might encounter, one is a noisy alternator. i bought this box+wire as an extra, and i'm not going to need it. The engine is a 350 , the alternator says (SAE J1171 Marine) on the back of the casing where the wire in question connects. Danchuk # 13245 has a natural finish and will work in any 1955-1957 classic Chevy that is running a 12SI style alternator as well as other vehicles you may have in your collection. Augment this with a wire from one of the alternator mounting bolts to the vehicle frame. Charging problems can be caused by electrical faults in the alternator or voltage regulator, poor wiring connections at the battery or alternator, or a slipping or broken drive belt. Block the pump or gear system connected with motors. But I've always wondered if leaving it like that would cause the alt's exciter to eventually drain the battery with engine off. Can someone please tell me the order in which the cable colors are placed at the alternator connector? There is a single thick red cable at one end of the connector and then 3 more thinner wires that. A short circuit is an abnormal connection between two nodes of an electric circuit intended to be at different voltages. You don't even have to connect the wire. Alternator Whine in Car Audio. A 75 amp alternator cannot replace a 65 amp alternator. How did my electrical plug melt? How do you know if an electrical problem is the appliance or the wiring melted plug Did my cable box or power strip cause cord to. If bad voltage, too high or too low, causes damage it will normally be the battery that takes the brunt of it. Occasionally, a symptom of this issue might be brighter lights, as the alternator produces more energy to overcome the resistance in a bad wire or a. what causes coil packs to melt If this is your first visit, be sure to check out the FAQ by clicking the link above. Something could be wrong with the alternator, the battery or how it was jump to cause too much amperage pull creating excessive resistence in a very small gauge wire. If you're lucky, the car just stops running. The company says wires can chafe against steering wheel trim, causing electrical shorts. 2 volts unless the cable-to-engine bolt (behind alternator) sucks or the negative cable itself is oxidized/corroded leading to high resistance wire. I have no idea how this could have happened. Included in the 18-circuit kit are trunk accessory, door locks, power windows, reverse switch and electric fuel pump. The 1-wire version is much easier to hook up, and is the preferred version to use for most tractor conversions. What is a one wire alternator? How much amperage do I need? Amperage Load Calculator. If it starts, then it is the alternator dragging down the electrical system. Safety First. I thought that maybe this wire was old and was shorting out some where on the frame or body, so I replaced it and tried the battery again. 8 A steady state. The diodes of the alternator can go bad, failing to transmit the required voltage. The large "BATT" terminal which gets connected to your battery positive. Wiring has a certain amount of resistance -- rated in ohms -- per foot. Disconnect the alternator wiring. The alternator has a good ground, the grounding wires from the body to the engine block ground out. In an alternating current electric power system, synchronization is the process of matching the speed and frequency of a generator or other source to a running network. Can anyone help me with the problem. Cut the butt splices off and then solder the two ends on the fusible links together against the one wire to the alternator. Wire size is based on 4' battery cables. it appears that it is only getting hot when the rig dont want to start right away and longer cranking happens. This unit has about 10k miles on it and was in use for about a year before the car was wrecked. The following alternator information has been created as a guide for charging system diagnosis and troubleshooting the alternator. Replace all the burned parts with new high quality units, including the wire to the alternator. /installation. No diodes or resistors or other junk are required for this conversion, although i did have to fabricate a new bracket and buy a longer belt. Coil On Plug Ignition: The Wired Differences Matt Dixon Southern Illinois University Carbondale, [email protected] If the engine cuts off, it is a sure sign that the alternator has died. You need to know the number of magnetic poles in your alternator. So the tally is: #1 Apple genius 1: kernel panics cause cables to melt, especially out of warranty phones. "How To" directions included. This would draw a large amount of current but not enough to trip the breaker. Online shopping from a great selection at Automotive Store. It was marketed in what I would consider to be a grossly misleading manner. On one hand, we know how frayed cords can cause overheating when the insulation is defeated, and strands of the hot wire touch strands of the neutral or ground wire (see Stand Your Ground ). Warning ("Idiot") Lights. This means that in the case of a fault, the wiring will be at risk of melting if the fuse does not blow quickly. This is why new dryer elements comes with two new red wires and wire nuts. i bought this box+wire as an extra, and i'm not going to need it. When your alternator begins to fail it can cause a variety of different electrical problems in your car, and eventually cause a breakdown. Since upgrading your alternator changes the amperage and not the voltage (on 12-volt systems), installing a higher amperage alternator is not going to cause your musclecar to burn to the ground or your wiring to melt. A permanent magnet flywheel alternator and solid state voltage regulator is used to charge the battery on the initial coach configuration (dedicated onan battery, most have been upgraded to share battery with house and are charded via the engine alternator and AC to DC converter). CORRECT WIRE SIZE IS CRITICAL: It is very important to use the correct wire size to connect the alternator to the battery. Stalling the motor (When motor does not start due to heavy load). I checked it by turning the key on(not starting) and taking the blue wire loose and when I read it with the meter it only read. Steel corrodes because it is not a naturally occurring material. Can anyone help me with the problem. The diodes in an automobile's alternator serve the same function as a one-way check valve does in a hydraulic system. That could result in wires melting, but if you have connections that are getting real hot, that is due to resistance. The alternator is from pep boys so its a prostart brand. Most likely they have not protected the med. You need at least a multimeter for that. The hot wire scent can be caused by an overheated alternator, one pushing too much power through the rotor and stator. The only tool you need to troubleshoot car wiring problems is a simple multimeter, either digital or an old analog meter with a needle, as comes with some ignition timing kits. But if you have to replace the alternator, you have options. not have a good connection, and in some cases may melt the end of the cable off and cause a fire. battery and alternator wiring problem - 99 Toyota camery : the wire between new alternator and battery gets hot, melted casing, and the fuse didn't bl × We use cookies to help our site to work, to help us understand how it is used, and to tailor advertising on this and other sites. thats a common thing. The alternator wire has the potential to supply a constant 12+ volts to any of the others ( which are to ground) and act as a heater wire inside the harness, getting hot enough to melt all the others. Grounded alternator casing appropriately. The oil pressure gauge will work with a new sending unit, which is on the back of the engine behind the carburetor, but only after you have fixed the regulator in the temp gauge. Place the crucible in the foundry. NOTE:1-Alternator must be disassembled to reinstall pulley properly 2-Using a 2 Groove Factory A/C Alternator Pulley with a single belt , non a/c application, will be misaligned and may cause a Intermitant Belt Sqeal 3-This pulley works with some of our BU A/C Compressor Brackets. So my question is do you think it's an alternator problem or am I missing something that would cause this. The alternator has a good ground, the grounding wires from the body to the engine block ground out. This unit has about 10k miles on it and was in use for about a year before the car was wrecked. Uhh, a missing ground wire does not tell the VR to charge. If the battery is dead, it does not mean this is the only problem you now face. There may be a plastic tab on the alternator post. It was marketed in what I would consider to be a grossly misleading manner. Below are five common causes for an alternator to go bad. The current and failure mileages were 54,550. Most people will just swap out the generator for a typical 12 volt AC Delco 10-SI alternator. Put in another new alternator and battery and the new alternator overheats. Shop for cheap price What Causes Saturated Fats To Melt. Before about 1980, there were no fusible links on alternators, but after that it is common practice to have a fusible link between the alternator and battery to prevent fires and wire burning up in the unlikely event that someone installs a battery with the polarity reversed or if a diode in the alternator fails. Connect a test light to the fuse link by attaching the ground wire on the test light to an engine bolt and touching the probe end of the light to the bottom of the fuse link wire where it splices into the alternator output wire. Aluminum is in use by the utility companies for the transmission of electricity since the early 1900’s. Use this guide for that. Maybe its melted? Or is there a knack to removing it? Update:. If I disconnect the EXC wire at the alternator, the ign light goes out on the switch panel. Simply touching the jumper wire to the terminal will cause the alternator to start charging, and remain so as long as the engine is. The wire at the back of the alternator melted off the eyelet, and the wire was scorched, even under the boot. Researchers have discovered that the earth is moving underneath the melting ice and pushing the rocky island up more than an inch a year. The subs have all been wired correctly. I agree that the alternator wasn't affected. Leave alternator on the engine. I will be getting a replacement alternator, but wondered if there should be anything else I need to check? Next problem: How do I get the big plastic wire block off? its the circular one holding 3 cables at the front of the unit. I agree with what you say. The alternator fuse has tripped twice in the last 2 days, after running the plane for a 30 min approx and the mechanic tells me that 90% of the time this is a sign of a bad brushes in a failing alternator. Search on the interwebs for "wire guage safe load" and youll find a table that will guide you to picking the right size wire. i have a newer mint condition fuse box with all new fuses in it, along with the alternator wire which you will probably need to replace too available. The first is the wire for the alternator is pinched or shorted to the chassis. The crimper tool crimps 14 to 0 AWG copper and aluminum wires using steel crimping dies. Attach a frequency counter, tachometer, or dwell meter to the field control wire on the back of the alternator. What is the best slogan for''When we are immune''?. Can anyone help me with the problem. I have a 2003 Subaru Outback 2. In some cases even a new stock size belt will slip. • Never use a Mega-Ohm tester on an alternator. Block the pump or gear system connected with motors. The blue wire that plugs to the alternator field melted all the way to the firewall plug. On older vehicles, the battery light would turn on the alternator light when the alternator output or battery voltage dropped below a preset value. Once a wire gets hot, the heat can travel along the wire until it gets to an electrical connection, such as a plug in a wall socket. That can also explain why you are having trouble starting. DETROIT — Fiat Chrysler is recalling over 1. Without a fuse or some kind of overload protection the amperage running thru the wire can also melt the insulation and cause a fire. You don't say what year and model you own, but if a 97 Trooper, then the regulator is internal to the alternator, and you may wish to get a new one. sounds like the wire from the alt to the battery is a piece of shit. If it’s in the range, it’s good. Re: Need Help Wiring a Mando Alternator to a Mercruiser you can get a marine one wire delco alt on ebay, i did my boat with one, one wire to battery one to key and its done. Small tie wraps. MELT developed by manual therapist Sue Hitzmann, is the very first Hands-off Bodywork® method developed for the general public as a self-care tool for chronic pain. Below are five common causes for an alternator to go bad. Then go to the Nutshell or full Troubleshooting page for step-by-step help to find the cause of your problem, and check the MENU above. Wiki User 09/18/2010. It's great for winter time feeding. Clip a jumper wire to the positive post of the alternator, or on the battery side of the iso-lator, if an isolator is in use (see Figure 11). Is this the wire you're referring to? It could either have a bad ground to the inner fender, or be full of corrosion. Alternator Wiring Kit 555 -10510 100 Amps 8 gauge 150 Amps 6 gauge 200 Amps 4 gauge It is very important to use the correct wire size to connect the alternator to the battery. Truck fires can have many and varied causes and the most common causes of heavy-vehicle fires are: Arcs on the starter (or battery cables), the alternator cable or the positive feed wire into the cabin. just another jackass ford employee. Don't have a volt meter but used a test light that will tell if hooked from positive to negative, or negative to positive. Electrically, what causes a fuse to melt? - Electrically - what causes a fuse to melt instead of break. Noticed my headlight low beams cutting in and out. Its soldered connections may melt if too much current flows through them. • The joint can also break,. Batteries will buffer most damage caused by out of range voltage issues. The positive wire only goes to the starter and the charge wire only to the alternator and the other wires to a fuse link holder. 5 volts, meaning the output of the alternator SHOULD have a complete connection to the battery for charging it. The Mobile Element Locator Tool (MELT) is a software package, written in Java, that discovers, annotates, and genotypes non-reference Mobile Element Insertions (MEIs) in Illumina DNA paired-end whole genome sequencing (WGS) data. My car has an automatic transmission. NOTE: some alternators back-feed power through the alternator and out the exciter wire. Online shopping from a great selection at Automotive Store. As you can see in the figure (the arrow), this circuit is the main wire that comes out from the alternator. Indicators that warn of an impending alternator problem can include the dashboard warning lights, a growling or whining noise from the engine compartment, and the smell of burning rubber or electrical wires. ShoutChat Box: Comment Guidelines: Do post respectful and insightful comments. This is known as the dip transfer mode of metal transfer. The blue wire is 12 V supply, via the bulkhead and key switch. A loose wire connection will cause high resistance which will cause heat and eventually cause the wire insulation to melt and when the bare wire touches cabinet ground it will pop and spark. Even a stock alternator is capable of massive voltage output, but is regulated to around 14V through the voltage regulator. The power wire plug is prone to melt and even cause an underhood fire. Terrible smell of melted plastic. This is often due to an overtightened fan belt wearing down the unit. What that looks like to me is that the ground wire contacted the B+ terminal somehow, shorting it out. The wire inside a light bulb is identical, except it's a sealed unit that contains a gas which stops the wire melting. The most recently reported issues are listed below. New harness on the way from MBparts at £51 its not worth trying to fix it. The alternator system is responsible for keeping your battery charged during operation by changing the current from AC to DC. I've never had any trouble with having something too well grounded, so I did. Depending upon the maximum output of the alternator, use the following chart as a minimum wire size guide. Wire Forming Tool This handy wire forming tool makes every bend and eye needed for spinners and spinner parts. Tuff Stuff does recommend upgrading the charge wire to a larger gauge (smaller number), as the factory wiring might not be capable of carrying the extra amperes without melting. Mercury Cougar Battery Light Due to Damaged Alternator Wire Harness Connector - 64 reports. Brushes inside the alternator cause some sparking when the alternator is charging. 2 Large lugs (one with wire is fusible link). If this melts it usually means that the ground strap between your engine and the frame is missing or has a bad connection. You need to make some power and ground voltage drop measurements at the alternator stator and regulator circuits to see if anything goes missing or wacky when it quits charging. This fuse will protect your car from fire in case any portion of the wiring comes loose or is severed or melted and comes in direct contact with the car chassis causing a dead short. This results in an electric current limited only by the Thévenin equivalent resistance of the rest of the network which can cause circuit damage, overheating, fire or explosion. This will do the same thing as. Alternator Wiring Harness by Genuine VW. Alternator slippage and undercharging can also be caused by a bad alternator pulley. The green wire that comes out of the regulator that goes back to the second field had broken strands at the connecter and broke off after a couple of wiggles. This is your first step. Cut the butt splices off and then solder the two ends on the fusible links together against the one wire to the alternator. I thought that maybe this wire was old and was shorting out some where on the frame or body, so I replaced it and tried the battery again. If it's factory, the wire is only like a 8-10ga. Why does my new alternator have a smaller pulley? Why is output so low at idle? Can I use underdrive power pulleys? Will a higher amperage alternator cause any problems with my stock electrical system?. Since resistance produces heat, a smaller wire carrying electricity of a given voltage and current will heat up faster than a larger one. You just shunted the current to gnd, upstream of the alternator's field. This wire goes to the battery (or to the main under-hood fuse box and then from there to the battery). When steel corrodes, the resulting rust occupies a greater volume than the steel. If the wires supplying an outlet are too small for the load, the terminals can heat up enough to melt the plastic faceplate. buck toenges,Sep 5 2009 wrote: I have a 1 wire alternator set up for my '53 cj3b. I have the alternator wire from the wiring harness hooked up at position #2 on the alternator, position #1 on the alternator is what appears to be a ground connection on my alternator (black wire with a ring connector on it) and I have that routed to the battery stud (which I am now thinking is incorrect). The alternators can wear prematurely. Electrical and Wiring Transmission Problems Car Repair Topics Car Making Noises Car Stereo Repair Heating or AC Issues Motorcycles and ATVs Tricks of the Trade Truck Repair Advice Site Options: Login Sign up here!. The hot wire scent can be caused by an overheated alternator, one pushing too much power through the rotor and stator. The alternator's windings and internal wiring has resistance, and that causes power loss and heat. Excessive loss here can cause the batteries to not charge properly. Need help determining cause of a melted fuse holder Archived. The alternator fuse has tripped twice in the last 2 days, after running the plane for a 30 min approx and the mechanic tells me that 90% of the time this is a sign of a bad brushes in a failing alternator. Any significant amperage through a weak contact point is going to do it. I was driving this morning and the lights started to dim and drained the battery. It will melt the WHITE 3-wire stator connector (VERY TYPICAL), and ultimately overheat the STATOR and Rectifier. A flexible steel sheath covers hot and neutral wires, which are insulated with cloth-covered rubber. One of the first symptoms of a bad or failing alternator is the need to jump start the vehicle on a regular basis. Mercury Cougar Battery Light Due to Damaged Alternator Wire Harness Connector - 64 reports. How did my electrical plug melt? How do you know if an electrical problem is the appliance or the wiring melted plug Did my cable box or power strip cause cord to. Alternator Whine in Car Audio. Even though the wire looks just fine from the outside, the internal strands get corrosion FIRST! So the first thing to do is replace every ground with new regardless. To reduce or eliminate this condition, be sure that the battery is clean. Complaint: bulbs in headlights and/or bulb holder melt causing wiring to melt and exposed wire causing extreme electrical damage. Right now i just have power running from both alternators to the front battery and then 2 0 gauge power wires running to the back batteries. If this problem DID NOT occur before the New Alternator installationthen one must assume a bad alt. The following alternator information has been created as a guide for charging system diagnosis and troubleshooting the alternator. So I have replaced the Alternator, Mechanic thought this was the likely cause the volt meter shows charging at 14 volts when the engine is running I suppose it could still be overcharging on long runs since this seems to happen after running for an hour. I just pulled the alternator out of my 97 F-150 and found the main power connection stud completely melted away. The resistance causes heat; enough to melt the connector, create a short circuit, or start a fire. An easy experiment to safely make a wire hot is to use a transformer and connect a bare wire between the two output terminals. Typically, the rate of increase, or rise time, of the current can affect the shape of the wire end. As you can see in the figure (the arrow), this circuit is the main wire that comes out from the alternator. What Causes Saturated Fats To Melt You will not regret if check price. There is no requirement to do this, but this prevents water from getting in the connection and wicking up the inside of the wire insulation or corroding the connector. Opened panel and that circuts neutral wire's insulation was melting. What would cause the alternator harness to melt? (2009 Ford Edge) My Edge wouldn't start 2x so we replaced the original battery which was approximately 5 years old. Once you get that problem isolated and repaired I woud think that the other problems would go away. Doing so will allow the maximum current from the alternator to reach the batteries. Have a GM alternator on my 8BA in my '36, wiring instructions say to run yellow wire from connector on back of alternator to ignition switch; do they mean the side of the switch that's hot all the time or the side that's switchable to hot, in other words the side that goes to the coil?. The alternator's job is to recharge the battery while you're driving once the battery has started the car. If it was just a loose connection, it would just spark and stuff, but not melt the wire.