Technical

16
information Ti 16-05 05 25 en-GB
Ti
Issue 3, 2008-09-08

Products affected

Truck in Series Bus in Series Engine

3 4 P G R T 3 4 K N
X X X X X X X X X X X
Miscellaneous:

Alternator troubleshooting and exchange table

Changes
The following changes have been made in this
issue:
• The test protocol on page 4 and 5 has been
changed.
• The part table on page 10 has been changed.
Background
Some uncertainty has prevailed regarding what
applies to alternators and alternator replace-
ment.
Upon investigation of claimed alternators is has
been discovered that many are free from de-
fects. It has also occurred that claims have not
been approved due to non-permitted external
changes (own repairs not adhering to this Ti).
There have also been occurrences of defect-free
alternators having been replaced, even though
the regulator was the only failing part.
Alternator
At the present time Scania has a number of dif-
ferent alternators, two different cable harnesses
and two different attachment systems.
Cable harness
The alternator may have either of two different
connections, depending on the engine cable har-
ness fitted.
• Multi-phase alternator
• Single-phase regulator
The easiest way to distinguish them is that the
multi-phase alternator has a multi-pin connector
while the single-phase alternator is connected
using ring cable terminals, see Fig. 1 and 2.
The engine and cab cable harness cannot be
changed without requiring extensive conversion
work. For this reason an alternator suitable for
the engine cable harness in question should al-
ways be ordered.

©
Scania CV AB 2008-09 1 (10)
Connection of multi-phase alternator

The following connections are used:

Figure 1
W = engine speed signal.

L = charging lamp earth cable.

15 = control signal from EMS. For the alterna-

tor to charge, a power supply of +24 V is re-
quired on this connection from EMS.
Grounding this connection turns off the alterna-
tor.

These connections are available but not used by

Scania:

BS = enables the voltage to be increased.

DFM = shows amount of current used com-
pared to current available.

Example of multi-phase alternator, connect

with connector

Figure 2

Example of single-phase alternator, connected

using ring cable terminals at 1

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Scania CV AB 2008-09 Ti 16-05 05 25 Issue 3, 2008-09-08
Troubleshooting alternators
To facilitate troubleshooting and to reduce the
number of rejected claims, a test report has been
prepared as a troubleshooting tool. Through
these tests, it will also be possible to decide
whether changing only the regulator will be
enough.
Transport
Since the alternator will be reconditioned it is
important to make sure it is correctly packaged
to prevent damage in transit.
See packing instructions in the information sent
out by the distributor.

No repairs may be attempted on claimed alter-

nators. Only change of complete regulator is ap-
proved for Bosch alternators (Scania original).

Note: The regulator on Valeo 90 A shall not be

changed. Instead, change the entire alternator to
a Mitsubishi Electric 100 A.

Note: There is a brush kit for Mitsubishi Elec-

tric 100 A that is to be used instead of changing
regulator.
Charging lamp - if the charging lamp comes
on it indicates a fault in the electrical system but
not necessarily a faulty alternator. Check fault
codes on the control unit* and troubleshoot the
alternator before changing it.
Do not change the alternator when it has inac-
tive diagnostic trouble codes. Trouble codes in-
dicate malfunctions in the system, the test
protocol on page 4 shall be used to determine if
the alternator is the failing part.
*Only applies to P-, G-, R-, and T-series.
Work description
Work description for:
• 4-series, see Workshop Manual 16:06-41,
Battery and alternator, Function description
Troubleshooting Work description.
• P-, G-, R-, and T-series, see Workshop Man-
ual 16-05 Electrical system, Alternator.
Note: When changing from Valeo 90 A to Mit-
subishi Electric 100 A on a vehicle without co-
ordinator, an adjustment shall be done acc. to
Workshop Manual 16:06-41; Battery and alter-
nator; Alternator; Change.

The reason for this is that Mitsubishi Electric

100 A, like Bosch 65 A, is 6-pin while Valeo 90
A is 8-pin.

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Scania CV AB 2008-09 3 (10)
Test report
A more detailed explanation of the test protocol is given after the protocol.
2. Distributor no. Claim no.

Value
Test Checking Measured Accepted Fault
1. Charging ❒ Bosch 55 A: > 15 A & 28 V
test 1a. Output
test ❒ Bosch 65 A: > 35 A & 28 V
❒ Valeo 75 A: > 35 A & 28 V
❒ Bosch 80 A: > 35 A & 28 V
❒ Valeo 90 A: > 45 A & 28 V Go to step 1b Go to step 2

❒ Melcoa 100 A: > 45 A & 28 V

❒ Bosch 100 A: > 40 A & 28 V
❒ Bosch 140 A: > 70 A & 28 V

❒ Melcoa 150 A: > 80 A & 28 V

1b. Voltage 28 +/-1.0 V at 20°C Alternator OK
Go to step 3
test

2. Phase
measurement

Keep the volt-

Replace the
meter con- <250 mV Go to step 3
alternator
nected as
above, but
switch it to AC
mode.
a Mitsubishi Electronic CO
Continue on next page

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Test protocol (continued)
Value
Test Checking Measured Accepted Fault
3. Brush Bosch 55A: > 5.0 mm
lengthb
Bosch 65A: > 5.0 mm

Bosch 80A: > 1.0 mm

Change the
Valeo 90A: > 2.5 mm regulator or
Go to step 4
brushes. Pro-
ceed to step 4.
Melcoa 100A: > 5.0 mm

Bosch 100A: >1.0 mm

Bosch 140 A: > 70 A & 28 V

4. Slip ringsb The surface should be smooth Replace the

Go to step 4B
4a. Surface and shinyc alternator

4b. Rotor re- Bosch 55 A: 9.1 +/- 0.7 Ohm

sistance be-
tween slip Bosch 65 A: 8.4 +/-0.4 Ohm
rings (at 20°C)
Bosch 80A: 8.0 +/-0.5 Ohm

Valeo 90A: 11.2 +/-0.6 Ohm Replace the

Go to step 3
alternator
Melcoa 100A: 9.0 +/- 1.0 Ohm

Bosch 100A: 8.5 +/- 0.5 Ohm

Bosch 140A: 7.9 +/- 0.4 Ohm

4c. Leakage
voltage meas-
urement be- Replace the Replace the
> 10 MOhm (infinite)
tween the slip regulator alternator
rings and
frame.
a Mitsubishi Electric CO
b
Item 3 and 4 do not apply to Melco 150A
c Does not apply to 80A and 100A

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Scania CV AB 2008-09 5 (10)
Charging test
Note: Remember to never run an alternator
without connecting the batteries! The rectifiers Figure 3
may be overloaded and destroyed.

The charging test consists of two sub-tests: an

output test and a control voltage test. To obtain
a good result, the alternator should maintain a
temperature of 20-25 °°C. A higher temperature
could give lower current.

The tests can be performed without necessitat-

ing access to the alternator.

Output test

1. Connect an ammeter with current pliers and

a voltmeter to the batteries as shown in Fig.
3.
2. Start the engine and run it for a minute or
so. Then make a note of how much current
the batteries receive from the alternator. At
the same time, check that the voltage is not Connecting to batteries
below 28 V. Run the engine at approx. 500
rpm.
3. Connect the same measuring equipment to
the electrical distribution box, see Fig. 4. Figure 4

Connecting to the electrical distribution box

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Scania CV AB 2008-09 Ti 16-05 05 25 Issue 3, 2008-09-08
4. Keep the engine speed at 500 rpm and load
the system using the vehicle's power con-
sumers according to the test protocol, col-
umn Control value (Example of power
consumer, see table below).
Add the current you read off at the batteries
to the sum with which you load. Example
with 65 A Bosch alternator: If you got a val-
ue of 10 A by the batteries, you only need
to load the alternator with 25 A instead of
35 A, 10 A + 25 A = 35 A

5. Keep the engine running while you apply

the load. Take a voltmeter reading again. It
should still not be below 28 V.
Example of current-consuming equipment:
Cab ventilation fan at max. approx. 14 A
Coolant operated cab heater approx. 6 A
Radio approx. 1 A
Main beams approx. 6 A (does not apply to P-, G-, R-, and T-series)
Auxiliary lamps approx. 6 A (does not apply to P-, G-, R-, and T-series)
Heated seat approx. 2.5 A (P-, R-, and T-series: approx. 5.5 A in position 2)

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Scania CV AB 2008-09 7 (10)
Voltage test Brush lengths

Carry out this test chiefly if overcharging is sus-
pected.
1. Keep the ammeter and voltmeter connected
to the central electric unit as shown in Fig.
4. Run the engine at about 500 rpm.
2. Load the system with approx. 10-20 A by
means of various current consumers.
3. Let the engine run for awhile. The control
voltage on the voltmeter shall be 28 V +/-
1.0 V at 20 °C. For Euro 5 (not incentive),
the control voltage shall be 28 V +/- 2 V.
Note: For a satisfactory result, the batteries
should be fully charged, that is, have a maxi-
mum current consumption of 10 A.
The ends of the brushes should be shiny and
concave to make good contact with the slip
rings.
Measure brush length between the end of the
brushes and the brush holder as shown in Fig. 5.
The regulator, or the brushes, should be
changed if the brushes are shorter than the min-
imum length.
Also check the slip rings when changing the
regulator or brushes.
Figure 5

If the result of the charging test is unsatisfacto-

ry, proceed with phase measurement and a
check of brushes and slip rings.

Phase measurement
Keep the voltmeter connected to the central
electric unit as shown in Fig. 4 but switch it to
AC mode.

The voltmeter should show a steady reading be-

tween 0 mV and 250 mV. If this is not achieved,
the alternator is defective and must be changed.

Measuring brush length

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Scania CV AB 2008-09 8 (10)
Slip rings

When the charge regulator with brushes has

been removed, access to the slip rings is easy
for the following checks:

Surface
Make sure the surface of the slip rings is smooth
and shiny. Poor contact with the brushes is indi-
cated if the surface is not shiny.

Rotor resistance
Rotor resistance is measured between the slip
rings with an ohmmeter as shown in Fig. 6. Figure 6

Leakage voltage measurement

The ohmmeter should indicate infinity (at least
10 MOhm) when the leakage voltage between
slip rings and frame is measured.

If checking the slip rings fails to give a positive

result, the alternator should be changed.

Measuring resistance of rotor

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Scania CV AB 2008-09 9 (10)
Choice of alternator when ordering a new one
When ordering a new alternator it is important to ensure that it can be fitted in place using the exist-
ing attachment points and cable harness. The table below shows the range of alternators available
as alternative units. The ampere rating of the alternator is specified as two distinct values: how
much the alternator charges at idling speed and at maximum rpm.

Mounted Alternatives
Alternator Output Part Alternator Output Part
Bosch N1 10/55 A 1 117 252 - - -
Bosch N1 10/55 A 1 105 367 - - -
Valeo /75 A 1 307 454 - - -
Bosch N1 30/65 A 1 409 378 Melco** 52/100 A 1 516 176
Bosch N1 30/65 A 1 409 380 Melco** 52/100 A 1 525 447
Valeo A14VI 40/90 A 1 440 768 Melco** 52/100 A 1 516 176
Bosch N1 30/65 A 1 409 378
Valeo A14VI 40/90 A 1 440 769 Melco** 52/100 A 1 525 447
Bosch N1 30/65 A 1 409 380
Valeo A14VI 40/90 A 1 448 150 Melco** 52/100 1 516 316
Melco** 52/100 A 1 516 176 Bosch N1 30/65 A 1 409 378
Melco** 52/100 A 1 516 316 - - -
Melco** 52/100 A 1 525 447 Bosch N1 30/65 A 1 409 380
Melco** 85/150 A 1 777 301 - - -
Bosch NCB 1 35/80 A 1 475 570 Melco** 52/100 A 1 777 464*
Bosch NCB 2 40/100 A 1 475 569 Melco** 52/100 A 1 777 464*
Bosch T1 /120 A 460 675 - - -
Bosch T1 70/140 A 475 885 - - -
Melco** L3B 52/100 A 1 888 010 - - -
Melco** BLA 86/100 A 1 794 784 - - -
* See Ti 16-07 09 27, New alternator as spare part.
** Mitsubishi Electric CO

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