Reducing Electrical Cost and Minimizing Downtime Brian Thompson National Fleet Manager 4/23/17

Today’s Issues Staying Ahead of the Curve for Electrical Requirements EPA regulations Idle restrictions causing major increase in starts/stops and lack of run time Battery and reserve capacity demands Driver Habits and Demands

Reducing Cost & Minimizing Downtime Troubleshooting Industry standard of good parts returned 25-30% Leads to improper diagnosis resulting in repeat road call/towing Test Equipment – Voltage Drops System Design/Specifications TMC RP 129A Understanding Electrical Applications Alternator Output Requirements Battery Reserve Capacity System Maintenance Corrosion Loose Connections/Crimps etc

The Electrical System Basics Specing Basic Steps Always treat as a system Spec the right components for your needs Understand you applications Troubleshooting Basic Steps Visual Inspection Always start with the batteries Batteries should be at least 12.4 volts and test good before proceeding Test cables and circuits Proceed to components

Heavy Duty Electrical System

Batteries Provide Power to Start Provide Power for Accessories Regulate the Voltage of the System Limited Power Supply

Batteries CCA – Cold Cranking Amperes – A measure of the batteries ability to give a quick burst of power at cold temperatures (Cranking the Engine) RC – Reserve Capacity – A measure of the batteries ability to cover loads while there is no alternator output. ( Lights, Inverter, etc.)

Batteries – Lead Acid

Batteries

Batteries Cycle is discharge to 80% (12.4)

Batteries Generally Batteries at a low state of charge can consume 30- 35 Amps each if available 3 Battery System – 90-105Amps 4 Battery System – 120-135Amps LVD Set-points 12.1 – 11.8  State of Charge Sealed or Flooded Lead Acid Gel battery AGM battery 100% 12.70+ 12.85+ 12.80+ 75% 12.40 12.65 12.60 50% 12.20 12.35 12.30 25% 12.00 0% 11.80

Battery Testing Testing with Carbon Pile Load Tester Use testing adapters! Remove surface charge by applying 300 amp load for 15 seconds Read terminal voltage of battery. If 12.4V or better proceed to next step. If less than 12.4V recharge battery and repeat surface charge removal Adjust carbon pile to apply one half of the CCA rating. Maintain load for 15 seconds and record terminal voltage. Estimate battery temperature and refer to chart on next page.

Battery Testing Estimated Battery Temp Voltage Not to Fall Below 70F or 21C 9.6V 60F or 16C 9.5V 50F or 10C 9.4V 40F or 4C 9.3V 30F or –1C 9.1V 20F or –7C 8.9V 10F or –12C 8.7V 0F or –17.8C 8.5V

Cables TMC – System Recommendations Alternator Circuit .5Volt Drop @ Alternator Rated Output Starter Circuit .5Volt Drop @ 500 Amps

Alternator Spec Considerations How long are you going to keep your truck? Brush versus Brushless Brush style – Typical low cost standard Alternator Brushless – Premium – Longer Life Brushless – fewer moving parts for improved durability How many amps do you need? Output / output at idle Indentify application requirements High out applications Remote Sense for improved battery charge time and life Over spec’ing provides longer system and alternator life Fuel economy – high efficiency alternators designed for substantial savings

Performance

Remote Sense

Alternator Feature Focus – High Efficiency 60%vs 68% 60%vs 75% Higher Efficiency = Less Horsepower Draw From the Engine

Alternator Trouble Shooting

Alternator Trouble Shooting Cable Drop Test Using Load Tester With engine off connect leads of load tester to alternator output terminal and ground. Connect a separate voltmeter to the batteries Adjust load tester to the rated output of alternator Read voltage at load tester and read voltage at separate voltmeter.

Alternator Trouble Shooting Load Tester Voltage Drop Results Voltmeter Reading At Battery – Voltmeter Reading At Alternator = Total Voltage Drop 12.4V 11.1V =1.3V drop The Maximum Allowable Voltage Drop is .5V

Alternator Trouble Shooting Determining which cable has the problem Move the positive lead of the voltmeter at the battery to the ground post on alternator. Connect negative lead of voltmeter to negative post of the battery. Adjust load tester to full rated output of alternator. Record reading at separate voltmeter. Note! The use of small jumper cables for your voltmeter to reach connections is allowed

Alternator Trouble Shooting Determining which cable has the problem Move the negative lead of the voltmeter at the battery to the positive post on alternator. Connect positive lead of voltmeter to positive post of battery. Adjust load tester to full rated output of alternator. Record reading at separate voltmeter.

Alternator Trouble Shooting Load Tester Voltage Drop Results Voltmeter Reading for ground side Plus – Voltmeter Reading for positive side Equals – Total Voltage Drop .9V + .4V =1.3V drop Again The Maximum Allowable Voltage Drop is .5V

Starter Spec Considerations Over Crank Protection (OCP) (Typical 3yr/350K Warranty) Cold cranking speed performance Weight Voltage drops (based on TMC Recommended Practice (RP) 129 Loss results in .5v = 15 engine RPM Integrated Magnetic Switch (IMS)

Starter Trouble Shooting

Starter Trouble Shooting TMC Recommendations – Control Circuit 1.0 Volt Drop Delco - Remy

Starter Trouble Shooting

Starter Trouble Shooting

Starter Trouble Shooting Drop 3 - 4 = .3 Volts Load Tester 11.0 12.4 100 2 3 1 4 Delco - Remy

Starter Trouble Shooting Total Voltage Drop 1.4Volts Leg 1 (1 – 2 ) .5 Volts Leg 2 (3 – 4 ) .3 Volts Mag Switch (2 – 3) .6 Volts TMC Recommendation is 1.0 volt max

Summary Treat as a System Understand your application Battery Cables Component Understand your application Always start at the batteries

Summary Questions?

Thank You For Your Attention Our Vision A Clean, Energy-Efficient World Our Mission Deliver Innovative Powertrain Solutions that Improve Fuel Economy, Emissions & Performance Fuel Economy Emissions Performance