92 240 redSR alternator very hot,burns out

[SpeeDDrifT]

my swap was done by a shop, since then i have had many alternator related problems. i've rebuilt/replaced the KA alternator on my redtop SR three times in about 1.5 years. I am running dual FAL fans, moderate stereo equipment, nothing really extra drawing on the charging system except the electric fans. eastbear headlights wired to the battery.

the alternator gets hot to the touch (wouldn't want to put your finger on it for more than a few seconds) after running for about 30 minutes. That's not normal is it?

if i disconnect the pos/neg and pin wires from the alternator and run the car on the battery alone, lights, electric selt belts, etc do not work. is that normal?

i tested the voltage from the battery, block, and body and they are all right on the dot, with no variance.tested battery which was fine.tested the fan draw which was normal 13-14.5 v

i use an optima redtop battery.

please let me know if there is any other info that would be helpful in your diagnosis, i really appreciate any input you have. thanks.

[rogoman]

Have you tested the voltage at the battery while the alternator is charging the battery; it should be around 14v. If it's way over 14v, then the voltage regulator may be defective.

It's also possible that there may be a low resistance short somewhere in the system.