Service difficulty report · Wire · Piper PA28181

Difficulty date
June 21, 2021
Submitted
June 21, 2021
Operation
General aviation
Aircraft
N625ND
Make and model
Piper PA28181
Aircraft serial
2881161
Aircraft time
1,622 hours
Part
Wire
Condition
Failed
Location
Alternator
Stage of operation
CL
How discovered
O
Nature of condition
B, H
Precautionary procedure
A

As reported to the FAA. Reports are unverified, and codes are left as the FAA publishes them.

What was found

PILOT REPORTED WHITE SMOKE IN THE COCKPIT, FOLLOWED BY LOW VOLTS ANNUNCIATOR. PRECAUTIONARY LANDING WAS MADE AND AIRCRAFT WAS SECURED ON RUNWAY. AIRCRAFT WAS TOWED BACK TO MX HANGAR AND VISUAL INSPECTION WAS PERFORMED. THE ALTERNATOR POWER WIRE WAS FOUND TO BE FAILED AT THE CRIMP ON THE ALTERNATOR END. WE FEEL THE FAILURE WAS CAUSED BY AN IMPROPER CRIMP ON THE 96F7882 RING TERMINAL CAUSING BREAKAGE ON THE STRANDS OF THE ALTERNATOR POWER CABLE. THE BROKEN STRANDS OF THE CABLE PROVED TO BE INCAPABILE OF HANDLING THE POWER FLOW AND BECAME OVER-HEATED AND ULTIMATELY MELTED CAUSING THE SMOKE INCIDENT. THIS WAS NOT AN OEM CONNECTOR BUT WAS AN AMP REPLACEMENT THAT WAS NOT INSULATED. IT HAD BEEN INSTALLED WHEN THE OEM CONNECTOR FAILED AT THE RING TERMINAL DUE TO LACK OF SUPPORT AT THE ALTERNATOR POWER STUD.

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