Posted by Jon hagen on October 07, 2012 at 10:06:08 from (69.26.17.61):
In Reply to: 1440 Combine Alternator posted by Rich in Ont. on October 07, 2012 at 06:55:22:
" One of the small wires going into the alternator is constantly live and even with the key off produces a small spark when connected. Please note that I am not refering to the larger battery wire coming out of the alternator, but the lighter ones that are usually in a plug. The plastic plug is long gone and now the wires are indivdual. I believe it is a Delco alternator. Thanks in advance for the help.......Rich."
That combine came with a Delco 10SI alternator originally. You state the plug is long gone and the always hot wire makes a small spark when connected.
looking at the rear of the alternator case where the small wires plug in, you will see the case marked #1 on the left, #2 on the right. The wire that is hot all the time goes on the right hand # 2 terminal and the other which is hot only when the ignition switch is on, goes to the left #1 terminal.
I would say you have those wires switched which keeps the alternator field active all the time. This puts a constant 3 amp drain on the battery. causing the dead battery and warm alternator.
Please go to your local auto parts store and get a Delco alternator harness repair plug.(80 chevy) You will get a new plug with short pigtail wires and crimp splices to attach it.(about $3) This will keep the wires installed correctly and prevent a very real electrical fire danger. Without that plastic plug, the # 2 sense wire, which is always hot with full battery power and unfused, need only be bent about 1/8 inch to short to the alternator case and almost instantly burn up that # 2 wire.
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