Why Check the System I Know What’s Wrong! We all have Test Equipment.

Why Check the System

I Know What’s Wrong!

We all have Test Equipment

But We All Use These Testers!

Our Favorite Testers!

Question

I

If the units are 100% tested at the factory, why do I seem to get so many bad units?

Question

I

If the units are 100% tested at the factory, why do I seem to get so many bad units?1) I’m Just Lucky!

2) The Units Were Damaged In Shipment.

3) The Units Are Cataloged Wrong.

4) They Don’t Really Test Them At The Factory

5) The Units Are Not Really The Problem

Answer!

The product you receive has nothing to do with luck, and while occasionally products can be harmed in route, and cataloging errors can happen. We take every possible step to ensure the quality of the product we sell, and the vast majority of problems can be traced to some other member of the electrical team on the vehicle.

Warranty Returns1) 55% of all DEFECTIVE alternators function perfectly

2) 52% of all DEFECTIVE starters function perfectly

2013 Core Testing

Testing of the cores returned in 2013 show that over 33% of all cores tested good!

That’s 1 in 3 times were the replacement of the unit did not fix the problem

Most Alternator/Starter failures can be traced back to bad connections

Which Testers Do You Think Got Used?

Educational StuffEducational Stuff

The Charging TeamThe Charging System is much more than just the Alternator.

1) Alternator2) Battery3) Cables4) Tensioner5) Belt

Alternator!Alternator!

What an Alternator DoesWhat an Alternator Does1) Maintains the Battery2) See Rule #1

What an Alternator Does Not Do

1) Charge Batteries with Low Voltage

2) Run the Vehicle’s Electrical System

What is an Alternators Nemesis?What is an Alternators Nemesis?•Weak Batteries Weak Batteries

• Low VoltageLow Voltage•Wiring Wiring

• Frayed, corroded, loose Frayed, corroded, loose •The ElementsThe Elements

• Water, Oil, Dust, HeatWater, Oil, Dust, Heat

Voltage Drop Test

Why Is This Important?If we have a .8 volt drop on the ground side. The alternator is only “seeing” 11.8 volts on a fully charged 12.6 volt battery.• Resulting in alternator going wide open to correct drop• Alternator Overheats• Alternator Fails!

When replacing a Alternator/Starter always do a voltage drop test first. Most times the original failure is caused by those bad connections

Battery

Why is a Battery Like a Glass of Beer?

Why is a Battery Like a Glass of Beer?

Result – New Battery Can Be Installed at 70%

Battery State of Charge12.6 or Higher = 100% Charged12.4 or Higher = 75% Charged12.2 or Higher = 50% Charged12.0 or Higher = 25% Charged

Less than 12.0 = Discharged

Battery State of Charge

Diagnosis has to be Systematic! Always check battery first! Check for 12.6 volts at battery Load test battery Check belt tension – is it loose? Check cables and connections

Things to know about a StarterThings to know about a Starter

The Starter’s Enemies The Starter’s Enemies •Low Voltage Low Voltage

• Dead or undercharged batteriesDead or undercharged batteries

•Poor GroundingPoor Grounding• Loose cablesLoose cables• Poor mountingPoor mounting• Corroded Corroded

•Earth, Wind and FireEarth, Wind and Fire• Dirt, water, oil, heat, salt etc…Dirt, water, oil, heat, salt etc…

Mounting GroundLargest grounding surface on a Starter is the mounting flange.

What’s wrong with this picture?

Clean Block and Starter surface!

Cables and Terminals are Critical

Always Buy Quality Cables

If making your own cables, Solder and Heat Shrink

00 Cables solve a lot of problems….Bigger is Better!

Take the time and do it RIGHT the first time!

Simple Things to Prevent 1 in 3 Simple Things to Prevent 1 in 3

Simple Things to Prevent 1 in 3 Simple Things to Prevent 1 in 3 AlternatorAlternator

• Proper AmperageProper Amperage• Check WiresCheck Wires• Start with Charged Batteries/ Charging Start with Charged Batteries/ Charging

StationStation

Simple Things to Prevent 1 in 3 Simple Things to Prevent 1 in 3 AlternatorAlternator

• Proper AmperageProper Amperage• Check WiresCheck Wires• Start with Charged Batteries/ Charging Start with Charged Batteries/ Charging

StationStation

StarterStarterStart with “GOOD GROUND”Start with “GOOD GROUND”Check CablesCheck Cables

Questions?

Thank youThank you