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The Ultimate Alternator Project
Those of you who followed along with the updates from our Caribbean
cruise earlier this year, may remember that we experienced some alternator issues along the way. This was disappointing for a number of reasons because we had already spent a fair amount of time, effort and boat bucks trying to find a high output alternator that was also durable. Our goal is to not run the generator at all when under way, and to minimize generator time when anchored. The potential savings on generator fuel and maintenance add up to a big number. To that end we've installed a 2,000 watt inverter and a bank of 8 golf cart batteries with a total capacity of about 1,000 amp-hours. The inverter and battery bank work well together but the batteries eventually need to be recharged, and when underway, the alternator needs to supply inverter amps, recharge amps and onboard house loads like navigation equipment, lights, auto pilot, engine room blowers, etc. Peak alternator loads can easily approach 250 amps and average well over half of that. To make a long story short, no automotive alternator that we've tried has been capable of these loads over a long period of time, even those that have been beefed up with heavy duty components. We burned out a total of 4 over the course of 6 months in the islands. Repair and replacement was problematic to say the least. After consulting with Tim, our cheerful, ever helpful, resident alternator expert on "rec.boats", and a number of other sources, I decided that a fresh approach was needed. Enter a company called Leece-Neville, a division of Prestolite, that has been making heavy duty alternators for a long time. LNs are used all over the world on fire trucks, ambulances, busses, big trucks, heavy duty construction machinery, etc. Their big alternators make everything else look like a toy, weigh over 35 pounds and are priced accordingly. Many of the really big ones are north of $2K at full retail. Thanks to the internet and EBAY however, they are now becoming available at more reasonable prices. I was recently able to buy a unit that had been remanufactured to like new condition for about $400, a bargain compared to some of our previous repair/replace experiences. It is rated at 270 amps continuously at high temperatures, and is designed for fire trucks, ambulances and busses. http://www.prestolite.com/pgs_products/specs.php?item_detail_id=951&item=A0014867JB&produ ct=ALTERNATOR There are some downside issues however: It is designed for a so called J180 mounting bracket; requires multiple drive belts since it can use as much as 6 or 7 horsepower; and is not ignition protected for gasoline engines. Ignition protection is not an issue for our diesels, and fortunately the front pulley on a Detroit 6-71 can accomodate up to three belts. The mounting bracket was problematic however since the existing mount was for a Delco 2 inch foot. In exchange for a sizable boat buck fraction, a local machine shop fabricated a custom made J180 bracket from 1/2 inch cold rolled steel. In combination with some Grade 8 steel mounting hardware and a new adjusting arm, everything is now solidly attached, lined up and looking good with 3 brand new Gates Green Stripe belts installed. In testing it has put out well over 200 amps while maintaining reasonable temperatures. Stay tuned for the long term durability reports... :-) New alternator and bracket prior to installation with a beverage can for size reference: http://img140.imageshack.us/img140/3557/preinstallwithnewbracke.jpg After installation, with new HD belts and adjusting arm. The black detritus in the background is left over from the many previous alternators and belts which gave up their lives in that spot: http://img16.imageshack.us/img16/1462/installedimg0573.jpg Boat, with new alternator well hidden, docked last weekend on the Caloosahatchie River in southwestern Florida: http://img593.imageshack.us/img593/6797/img0567i.jpg |
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