Hey Guys, take a look at your plastic connector to the R/R.  I found a bit of overheated wire on one of the three phase wires coming from the PMA.  You can see that it discolored the connector area where the spade associated with the bare wire is located and seated.  That bare wire is the one that overheated and made it easy to crack and break off the insulation.  It also got hot enough to partial melt some of the other phase wires.  Crimps are all good, output wires good, so I'm scratching my head a bit on why this would overheat.  One of the A&P/IA mechanics I work with thinks it is most likely due to the fact that I had applied some dielectric grease to the terminal connections during install.  Evidently, a big "NO-NO" and certainly not recommended.  I am currently (bit of a pun there) still investigating that on the Matronics  Aero-Electric forum with the electrical gurus.  So, be heads up, pull those cowls and take a look at things pretty close every couple hours.

Views: 180

Reply to This

Replies to This Discussion

Wow David, could this mean there was very high resistance at the connectors? I wonder if that is why my prewired connector was so tight I couldn't remove it.

Certainly looks like things got HOT there. Good catch on the inspection.


New from Zenith:

Zenith Planes For Sale 

Classified listing for buying or selling your Zenith building or flying related stuff...


Weather Maps

Custom Instrument Panels
for your Zenith

Custom instrument panels are now available directly from Zenith Aircraft Company exclusively for Zenith builders and owners. Pre-cut panel, power distribution panel, Approach Fast Stack harnesses, Dynon and Garmin avionics, and more.

Custom Upholstery Kits for your Zenith Aircraft:

Zenith Vinyl Upholstery Kits

Zenith Apparel from EAA:

Zenair Floats

Flying On Your Own Wings:
A Complete Guide to Understanding Light Airplane Design, by Chris Heintz

Builder & Pilot Supplies:

How to videos from HomebuiltHELP.com

Developed specifically for Zenith builders (by a builder) these videos on DVD are a great help in building your own kit plane by providing practical hands-on construction information. Visit HomebuiltHelp.com for the latest DVD titles.

Aircraft Insurance:


West Coast USA:

Pro Builder Assistance

Pro Builder Assistance

Aircraft Spruce & Specialty for all your building and pilot supplies!

© 2019   Created by Zenith.Aero.   Powered by

Badges  |  Report an Issue  |  Terms of Service