Technical Data Booklet About Alternators.pdf

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Technical
Data Booklet
QX Components Ltd
We have created this Technical Data Booklet to put the industry jargon into plain
English.
There are useful tips in:
Identifying the layout and the hand of a unit.
Handy wiring hints.
Diagnosis of everyday fitment faults.
We hope this booklet acts as a useful tool when you are confronted with a question
but please bare in mind we are here to help and only a phone call away.
Kind Regards
Andy, Alan, Dave & Rick
The Sales Team QX Components Ltd
Should you require any technical assistance do not
hesitate to give Andy Shevlin or Dave Frost a call on
0161 746 7676.
Tel: 0161 746 7676
Great your customer has bought an
alternator
They can fit it and forget it, not quite true, 85% of all alternators fitted to cars with a
discharged / flat battery will fail within 30 minutes.
He must make sure his battery is fully charged, if it isn’t the alternator is not
designed to and cannot cope with the demand of handling the vehicles electrics and
charging a flat battery.
The likely result is an overloaded alternator which will blow the rectifier, rendering the
unit useless.
Common General Faults
Alternators:
•
No charge:
Loose or missing fan belt.
Break in wiring.
Blown / corroded fuse or fuse link.
Blown rectifier diodes, (often caused by jumpstarting a
vehicle without first disconnecting the Alternator).
Loose fan belt.
Poor wiring connections.
Poor battery condition.
Failed Regulator or Rotor.
Loose or damaged fan belt.
Loose pulley.
Worn Alternator bearing, (often caused by an over tightened
fan belt).
Blown warning light bulb.
Poor Alternator earth connection or broken wire.
Relay problem.
•
Low charge:
•
Overcharging:
•
Noisy:
•
No warning light:
•
Dim warning light:
Loose fan belt.
Loose wiring plug.
•
Continuous light:
Poor wiring connection (common mistake when
plugging in the A127 series is the small warning light
terminal gets bent over touching earth).
Loose fan belt.
Defective alternator.
Page 1
QX Components Ltd
Alternators (the jargon)
Internal Fan (Bird cage)
The conventional alternator for many years has been an alternator with both the fan
and pulley on the outside of the unit.
The internal fan or “bird cage” has just the pulley on the outside; it also has two fans
but these is fitted on the inside of the unit.
The fan is fitted internally to simply provide cooling to internal components.
INTERNAL FAN
Internal Regulator
98% of vehicles on the road today have an internally regulated alternator; the
regulator is either inside the alternator or bolted to the back of the unit.
A127 TYPE
BOSCH TYPE
Slotted Bracket
Some French models have an alternator with what we call a slotted front mounting
bracket; this aids in the fitment of the unit it also allows the fixing bolt to be removed
from the side.
SLOTTED BRACKET ALTERNATOR
Page 2
Tel: 0161 746 7676
Alternators and Starters with Coolant,
Fuel and Oil contamination don’t mix
Can you imagine pouring a few pints of oil into your washing machine motor; yes
your right it would not last very long.
Alternators and Starter Motors do not like such contamination either.
It gets between the brushes and the slip rings or armature, causing them to shred
and turn to paste.
The oil also impregnates the stator or armature and prevents the heat generated
from dissipating therefore causing the unit to overheat and fail.
If when you sell a unit and your customer gives you the old unit with evidence of
such a leak, please suggest the leak is repaired before fitting the new unit; after all it
is in his interests.
The most common vehicles that seem to suffer with this problem are Ford 1.8 diesel
engines and Volkswagen petrol engines.
Page 3

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