I have two engines each equipped with a 150 amp Series 6 Balmar alternator
. They both have 0000 wire attached to them.
In October 2013 the port engine
alternator's negative stud broke. I replaced the rectifier and changed how the negative and positive wires ran to it so that the wire would vibrate along with engine
more easily. But while doing routine maintenance
this week I noticed the negative stud on the same alternator
broke again. The break appears to show fatigue at the bend. Essentially I got two sailing seasons out of it.
I have checked with Balmar
and while they have experienced a several of these failures over the last year, their specs have not changed and their suppliers say nothing has changed on their end. The positive stud shows no issues nor does the starboard engine alternator.
I am now about to replace the rectifier again and am looking for suggestions on how to reduce the strain on this stud. I have thought of adding a short length of lighter wire between the 0000 and the stud or trying to reinforce the stud at the bend but would like to see what other ideas there are.