Alternators wear out over time. But placing them in the same category as tires, belts and hoses is a mistake.
Preventative maintenance can extend the functional lifespan of an alternator by years, even in cases of heavy use.
Maintenance to mitigate the effects of heat, vibration and contamination should be part of every fleet mechanic’s regular schedule.
Alternator care to save your fleet $$$.
The most important part of any preventative maintenance schedule for alternators in your fleet is a thorough visual inspection. A mechanic can spot the three major alternator issues easily.
Since heat is one of the leading causes of alternator failure, the alternator’s cooling system is the best place to start an inspection.
- For air cooled alternators, check the vents for obstructions and make sure the external fan (if installed) is in good condition.
- For liquid or oil cooled alternators, the inspection is more time consuming. Stay up to date with manufacturer suggested oil or other liquid coolant replacements. Check the coolant lines for newly developed bends or kinks and ensure vent or drain lines stay clean and clear.
Even small vibrations can cause catastrophic damage to an alternator over time. To combat vibration damage:
- Check the alternator’s mounting bushings quickly during any maintenance or repairs. Brushings wear out and leave the alternator in an unstable position in the engine. The associated vibration leads to the premature failure of internal components.
- Loose bushings also cause other problems if the alternator is grounded through its mounting hardware. Ensure the mounting hardware is secure and has not vibrated free.
Contamination can wear down an alternator over time:
- Check for external contaminants like dirt, leaves and other organic gunk that’s regularly kicked up into the engine during travel. Dirty electrical connections put the same level of strain on an alternator as a discharged battery does. A shortened lifespan commonly comes from filthy electrical connections. Other contaminants like oil or road salt can damage internal components if they get inside a unit.
Alternator care fleet mechanics may overlook.
Some external factors, like an over-tightened drive belt, can also cause an alternator to fail early. The same way a loose belt can prevent an alternator from charging properly, an overly tight belt can overload and damage the alternator bearing. Belt tensions should be checked at every maintenance opportunity.
An alternator may also fail prematurely if it takes on more of the electrical load than it’s designed to. Load test the battery on a regular basis in addition to checking and cleaning the battery terminals, cable ends and the electrical connections on the alternator itself.
Replace components, not entire alternators.
Fleet mechanics can prolong the life on an alternator by replacing certain components before they wear out.
- Check the regulator and brushes every 12 to 24 months. If the brushes are out of spec, this provides an opportunity to replace them before they start a chain reaction of failure in the alternator.
Replacing these degradable components before they fail won’t allow fleet mechanics to maintain a single alternator forever, it helps prevent sudden failures, keeping your vehicle on the road longer.
How to clean your alternators.
- Do not use petroleum based engine degreasers to clean the alternator.
- Do not use compressed air or a pressure washer to clean the alternator.
- Do not spray a cleaning agent or degreaser directly into any air inlet openings on the alternator.
Dilute any off the shelf degreaser to a 50/50 mixture with water before applying with a cloth or gently spray.
Place an order online today for your alternator replacement parts or for a new stockpile of replacement alternators so your fleet mechanic can swap out old units readily and get your fleet back on the road.
