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Mercruiser Alternator wire overheating – engine stops - tip
Problem: Engine would stop suddenly at various RPM’s. Low voltage indicated on dash voltmeter. Vessel: 1997 Monterey 180, 190HP Mercruiser Vortec V6 I/O, Thunderbolt ignition. Electrical system was upgraded to a dual battery system with isolation. OEM Mando alternator was replaced with Delco alternator since parts and service were more available and economical. Deep cycle batteries were used to allow extended use of lights, entertainment, and electronic equipment. When the batteries were discharged for about four hours the engine would occasionally die, without apparent cause. Less than 12 volts was indicated on the dash voltmeter. Upon testing it was discovered that when the batteries were partially discharged the orange wire from the alternator was too hot to touch. Voltage measured at the batteries was below 12 volts and was often 11 volts. At about 10.6 volts the engine would die. The alternator output wire was measured and calculated to be 10 gauge. Charts indicate 10 ga. wire is rated at 22 amps continuous duty. Alternator output is 55 amps or better. Alternator output wire was supplemented with 4 ga. wire directly to battery one. Voltage at battery and on dash increased to at least 13 volts. Orange wire runs cool. Engine ran for two hours continuously after four hour battery discharge with no problems. FYI -- Dick Harper Please change the "1" to a "-" for a valid reply address. |
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