MAINTENANCE COUNCIL MEETING - 9/8/2008

New Engines Have Driven Development of Next Generation Alternators and Starters

Everyone in the heavy truck industry is familiar with the impact of new EPA compliant engines. Truck makers have invested many millions to accommodate the new engines and end users have had to learn how to service their new power plants. The new engines have also impacted truck components suppliers – especially alternator and starter manufacturers. The increasingly higher under hood temperatures generated by the new engines has led to the development of alternators that can take the heat while still meeting the rigorous vibration and electrical current demands on today’s commercial vehicles.

Not your father’s alternator…

Engine’s manufactured in 2002 and earlier can use an alternator rated at 93 degrees Celsius. Engines manufactured in 2003 and later require the use of an alternator that can operate in temperatures of 105 to 110 degrees Celsius. Engineers are now working on alternators that will withstand 125 degrees Celsius – just in time for the 2010 engines. In fact, for the past several years, engineers at Prestolite, Inc. have made many enhancements to the company’s Leece-Neville family of alternators. For example, the 110-555 alternator (one of the trucking industry’s most recognized and widely models) underwent significant design changes and upgrades to survive and thrive along side new engines.  Key enhancements include:

A solid rectifier lead frame that creates a single, solid connection to all of the alternator’s high temperature diodes. The diode connections are welded and not soldered (solder can be compromised in extreme heat conditions).

Higher efficiency fan for greater air flow and cooling

Large ball bearings, both at the front and rear, increases operating life and provides better support for the higher belt loads and operating temperatures. Krytox® high temperature grease is also used to combat the heat.

Sealed brush cavity to reduce contamination and provide longer life than open brush systems

New engines have also had an impact on the starters. New electronically managed engines need to reach a minimum speed (typically around 100 RPM) before the electronic sensors will allow the engine controller to release fuel into the cylinders. As soon as the starter has created enough torque to successfully turn the engine over it’s the speed that it can achieve that will determine if the engine is going to start. The new Leece-Neville 8kW Titan 125 gear reduced starter has been engineered to provide maximum speed at the required torque, to start the toughest engines in the toughest environments. Extensive testing in Alaska showed that the Titan 125 can start the newest big bore engine at temperatures below 20 degrees Fahrenheit). The Titan series features an electrical soft start feature that is proving to be the most dependable way to eliminate milling of the ring gear. The soft start design slowly rotates the pinion as the starter is being engaged, ensuring that the pinion is fully engaged with the ring gear before full power is applied.

The Titan^TM 125 starter

New engine technology will continue to drive changes. Learn more about how Leece-Neville is helping the industry tackle the challenges of new engines by attending the September meeting located at Libby Hill in Greensboro located at 3011 Randleman Road .Please RSVP to sredmon@dieselequipment.com. We look forward seeing everyone then.