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Over The Rockies With No Alternator

And that was the good news…

[Credit: Joel Kimmel]
Gemini Sparkle

Key Takeaways:

  • During a cross-country flight, the pilot experienced an electrical system failure that escalated to a complete loss of avionics and radio communication, requiring an emergency return to KFNL.
  • Investigation revealed a major engine hardware failure caused by a factory assembly error: a missing/unspread cotter pin and loose components in the direct drive alternator, leading to metal contamination and requiring a full engine teardown.
  • Despite the engine being out of warranty, the pilot successfully presented evidence of the manufacturing defect, leading Continental to cover the significant costs for the engine repair and reinstallation.
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In late June 2021, I had a business meeting scheduled in Salt Lake City, Utah, so I was happy to have a good excuse for a cross-country flight from Ithaca, NewYork, in my 1979 Cessna 210N. I had an uneventful flight to the Northern Colorado Regional Airport (KFNL) near Loveland and Fort Collins, where I had planned to overnight and head to Salt Lake City InternationalAirport (KSLC) the next day. I filed IFR for KSLC via the northern route, which has somewhat lower minimum en route altitudes (MEAs). Shortly after passing the Medicine Bow (MBW) VOR, I noticed red flags on both Aspens (PFD and MFD), as well as major electrical discharge indications of the ammeter on the JPI930 engine monitor. I shut off all electronics except the Garmin GTN 750 and headed back to KFNL with ATC guidance. Denver Center suggested a landing at the Laramie airport (KLAR), but I feared there would be minimal maintenance facilities. Besides, the engine was running smoothly and I was in VFR conditions, so I elected to return to KFNL.

About 30 nm north of the airport, I lost radio contact with Denver Center as the GTN 750 screen and the rest of the instrument panel went dark. I connected the Icom handheld radio to my Lightspeed headset and continued trying to reach Denver and the KFNL tower. I was reminded that without an exterior antenna for the Icom handheld radio, its range is only a few miles. Radio communication with the remote KFNL tower was finally accomplished about 4 nm north of the airport as I entered a long left downwind for Runway 33. Denver had offered to give me block space for landing at KFNL, and they diverted traffic until after I landed. They also provided their phone number and requested that I telephone them immediately after landing. After parking the airplane, I called Denver Center and reported my safe landing. They thanked me, wishing me luck.

Jack Henion

Jack Henion is an instrument-rated private pilot, founder of Advion Inc., and a professor emeritus at Cornell University in New York.

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