Problem: Dead battery due to alternator not charging.
Solution Date: In Review- final solution not found
Failure Mode:
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- Alternator not charging
Root Cause:
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- Brush wire gets frayed if the brush is allowed to extend beyond its original position.
- Wire becomes frayed until remaining brush wire is unable to support the normal operating condition resulting in higher resistance and ultimately no output of the alternator.
- Found when the operator removed the protective cap the brushes would fully extend causing they fray in the wires.
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Solution:
- Updated Process Standards: Our supplier has revised their handling processes for regulators during assembly, ensuring each unit is supported correctly to prevent any undue stress on components
- Thermal Management Improvements: To combat the high heat conditions associated with 200A operation, we’ve started applying thermal grease to the rectifier heat sink. This change aims to reduce the temperature by 23-30°C, significantly extending the diode’s lifespan and overall unit reliability.
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If you have questions about this or our Reman products, please contact the Reman Technical Center at (888) WHY-REMAN or experts@cnhreman.com.