16:06-41

Issue 1

en

Alternator and Battery

100812

Description of operation Work description

1 586 719

Scania CV AB 1996-05

Contents

Contents

Description of operation General

Balance of charge .............................................. 3

Charging in winter ............................................. 4

Battery

General ............................................................... 5
Changing the battery .......................................... 5
Cleaning ............................................................. 5
State of charge ................................................... 6
Electrolyte level ................................................. 6
Charging batteries .............................................. 7
Jump starting ...................................................... 8
Battery heater ..................................................... 9

Alternator

General ............................................................. 11
Internal connections ......................................... 12
Rotor ................................................................ 13
Sizing the alternator ......................................... 14
Alternator current table .................................... 15

Fault diagnosis

.......................................................................... 16
Testing the charge ............................................ 18

Work description

Changing the alternator .................................... 19

Carbon brush length ......................................... 20
Rotor ................................................................ 20
Stator ................................................................ 21
Diodes .............................................................. 22

Specifications

.......................................................................... 24

Scania CV AB 1996

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Description of operation

Description of operation
General
Some vehicles have a wide range of equipment
with a high power consumption.
It is important that alternator output is matched
to consumption. An alternator which is too
small will reduce the life of the battery and
may cause problems with starting.

Balance of charge
The alternator should be able to supply power
requirements and provide an excess for charging (at least 10 A). The function of the batteries
should basically only be to start the truck.
An incorrect balance of charge means that too
much of the peak consumption is supplied by
the batteries. This results in reduced battery life
and may cause starting problems.
There are primarily two types of operation
which can damage the battery, namely
sulphating and cycling (repeated charging
and discharging).

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The charge balance is shown by the ammeter.

The reading should always be positive, showing that the alternator is providing an excess of
charge

Scania CV AB 1996

General

Sulphating

Charging in winter

If the batteries do not have time to recharge

between discharges, sulphating slowly takes
place.

In winter, the battery is difficult to charge and

its capacity is reduced. Vehicles which use an
auxiliary heater at night and which consume a
high level of current during the day (e.g. when
loading) can have problems with the batteries
failing to recharge between discharges.

When this takes place, the material in the positive and negative plates is converted to lead
sulphate, reducing the specific gravity of the
electrolyte. If the battery is then left standing,
the lead sulphate crystals grow together,
mainly on the negative plates.
The battery is referred to as sulphated. If sulphating is allowed to progress too far, it cannot
be inhibited by charging. The battery gasses,
meaning that the current simply splits the water
into hydrogen and oxygen. Battery capacity is
permanently reduced.

A battery which if left in a low state of charge

for long periods may suffer from sulphating.
The battery may then need to be changed.
A battery heater will help a cold battery to
charge more quickly (see Battery heater).

Cycling
Each time a battery is discharged, a portion of
its service life is used up, even if it is subsequently recharged. Batteries can normally provide around 100 - 200 cycles with major
discharge and recharging, depending on battery
design.
If discharging and recharging takes place often,
the lead material becomes detached from the
plates, leading to a loss of capacity and even to
short-circuit in some of the cells.
Cycling can arise, for instance, when an auxiliary heater is used when the engine is switched
off.

Scania CV AB 1996

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Battery

Battery
General
The vehicles are equipped with two 12 V batteries, coupled in series, to provide 24 V.

+24 V

Changing the battery

Do not disconnect the batteries when the
engine is running. This can cause damage to
the alternator or other electrical components.
Disconnect the earth lead (negative terminal)
first, and then the other connections.

12 V

12 V

Fit the leads correctly. Start by connecting the

positive lead and then connect the earth lead to
the negative terminal of the battery.

102005

Fitting

Do not confuse the battery connections. The

alternator or other electrical components may
be damaged.

Cleaning
Clean the batteries, leads and battery box. Corrosion and dirt can cause voltage loss or even
discharge.
Apply Vaseline to the terminals.

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Scania CV AB 1996

Battery

State of charge
Check specific gravity using a hydrometer. In a
fully charged battery, this should be:
at
at
at

+20 C
0 C
-20 C

1.28
1.30
1.31

If specific gravity is lower than 1.24 at +20 C,

the battery must be charged. A discharged battery freezes at -5 C.
Avoid boost charging (see Boost charging).
The battery is damaged after repeated charging.
Note: If the batteries have different charges,
they must be charged separately.

Electrolyte level
The electrolyte should be level with the upper
part of the round, white plastic ring which can
be seen inside the battery when the cap is
unscrewed.
Top up with distilled water as necessary.
Note: Sulphuric acid or electrolyte improver
must not be used.

Scania CV AB 1996

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Battery

Charging batteries

State of charge
The current must be no greater than 10 % of
battery capacity. This means that a 170 Ah
battery should be charged with max. 17 A.

WARNING!

An explosive hydrogen gas mixture is

generated when charging the battery.
Do not smoke and make sure that there
are no appliances which could generate
sparks in the vicinity.

Boost charging
When boost charging, the battery is charged
using a higher current for a shorter period.

General
Cell voltage increases during charging. Gas is
generated at about 2.3 - 2.4 V.
The charging time for different batteries varies
depending on the size of the batteries and the
charge current.
If it is necessary to top up with distilled water
when charging, this should be done first. If not,
the water will form a layer at the top of the
cells and may cause the batteries to freeze at
low temperatures.
Note: In a fully discharged battery with low
electrolyte level, the level may increase
during charging. If the battery is fully
filled before being charged, the electrolyte may overflow.

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Batteries which have been slowly discharged

(sulphated) should be charged with no more
than half the current.

IMPORTANT! Charging may only be done

with the cable terminals disconnected or when
the power is switched off at the battery master
switch.
Charging should end when gas starts to be
generated.
Note: Boost charging reduces the life of the
batteries and should therefore only be
done in an emergency.
When charging old batteries, lead material
may become detached from the plates, causing
reduced capacity and even short-circuit in
some of the cells.
Sulphated batteries must not be boost charged.

Scania CV AB 1996

Battery

1
+

101002

Jump starting

Proceed as follows:

Both vehicles must have a 24 V electrical system. If the source vehicle has a higher voltage,
there is a danger of the control units being
damaged.

Start the engine on the fully charged vehicle.

Do not stand close to the batteries when using

jump leads. Explosive gas is generated in the
same way as when charging the batteries. A
battery can explode causing serious injury.

3 Connect to on the fully-charged

battery.

Carefully follow the instructions in order to

avoid injury to persons or property.
Use heavy-duty jump leads - at least 25 mm2 with insulated clips.

1 Connect to + on the weak battery.

2 ... to + on fully-charged battery.

4 ... to the chassis frame a distance from the

battery in the vehicle with the discharged
battery. This last cable may spark when it
is connected. If the protective paint on the
chassis frame is damaged, it must be
touched up immediately afterwards.
5 Start the engine on the vehicle to be
charged. Do not stand near the batteries.
6 When the engine has started, first detach
the cable from the frame and then the other
cables.

Scania CV AB 1996

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Battery

Battery heater
Vehicles used for sleeping in at night or at temperatures below -20 C should be equipped
with a battery heater. A battery heater warms
the batteries to 10 - 15 C, reducing charging
problems.
The battery heater is automatically switched on
below about -4 4 C and only when the alternator is providing a charge.
Insulation helps to maintain the heat in the batteries. This makes starting easier. A warm battery has almost twice the capacity of a cold
one.

Ah
Example: The following example shows how
battery charge is affected by temperature and
driving times.
A vehicles 160 Ah batteries are discharged of
80 Ah. The graph shows approximately how
much charge is replaced during 8 hours of
driving. With no battery heater, the battery is
recharged with 40 Ah at -20 C. With a battery
heater, twice as much charge is replaced,
80 Ah over the same period.

160

B
140
C

120
100
80
1

Also see 16:06-42 for further information.

8 h

A) +20 C, 100 % charged

B) -20 C, 100 % charged with
battery heater
C) -20 C, 75 % charged without
battery heater

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Scania CV AB 1996

Alternator

101345

101171

Valeo 90 A

Bosch 65 A

10

Scania CV AB 1996

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Alternator

Alternator
General

F1

F1

The charge regulator ensures that the alternator

provides the correct output voltage. This is a
transistor regulator, manufactured together
with the brushes as a single unit, and cannot be
adjusted.

F2
F2
F3
F3

101122

The alternators have three stator windings and

are of three-phase type. The stator windings
can either be star-connected or delta-connected. The alternating current generated in the
three phase leads as the rotor turns must be rectified in order to, for example, charge the batteries. Rectification is via a diode bridge.

Delta connected stator windings

(90 A alternator)

F1

F1

0
F2

F3

F3

101120

F2

Star connected stator windings

(65 A alternator)

Special instructions
Make sure that the batteries are connected
with the correct polarity. If the poles are
reversed, the alternator diodes will be
destroyed.
Never detach the battery or alternator when
the engine is running.
It is not necessary to detach any leads from
the alternator when arc welding. connect the
welders earth clamp as close to the weld
point as possible.

Charge lamp
The charge lamp should go out when the
engine is started. If the lamp remains on, the
alternator is not providing a charge (the lamp is
then connected to earth via the alternators
connection D+ to DF- (see Alternator).

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Scania CV AB 1996

11

Alternator

Internal connections
5

Rotor winding
Stator winding
Rectifier diodes
Capacitor (suppression)
Field diodes
Charge regulator

4
3
2
1

101118

1
2
3
4
5
6

Internal connections, 90 A alternator

Connections / markings

B+ Starter motor and battery+. Supplies the

various current loads in the vehicle and
provides charge to the battery.
Designation in diagram: 30.
D+ Charge lamp. Switches off the charge
lamp by providing a reverse voltage.
Lights the lamp by providing earth and
provides excitation current to the rotor (at
start).
Designation in diagram: 61.

3
2

1
101119

W Speed (frequency) signal. A number of

vehicle systems use the alternator to read
engine speed. Frequency is dependent on
the number of poles.
Designation in diagram: W.

Internal connections, 65 A alternator

B- Earth. Note that the connection is isolated

from the alternator casing in trucks with
2-pole ADR.
Designation in diagram: 31.
Also see connection diagram 16:02-03.

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Scania CV AB 1996

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Alternator

Rotor
The rotor in an alternator consists of two clawshaped metal poles (north and south) which
enclose a coil (magnet winding), all mounted
on a shaft.

101136

The coil is supplied with direct current from

the field diodes, via slip-rings, to magnetise the
claws. An 8-pole alternator has eight north and
south poles, and a 6-pole alternator has six.

The rotor has lines of magnetic force running

from the north poles to the south poles. Supply
to the slip rings is with brushes via D+ to DF-.
D+

DF

101137

In order to prevent alternator voltage from

surging (above about 28 V) as engine speed
increases, field current is controlled by the
charge regulator. Control is achieved by
earthing DF-.

Since current flows through the rotor as it is

rotating, a charge current is generated in the
phase windings of the stator.

101138

The three-phase alternating current which is

generated must be rectified to provide a direct
current. This is done with the help of diodes.

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Scania CV AB 1996

13

Alternator

Sizing the alternator

Power consumption (A)

The alternator should be able to provide an

excess charge (at least 10 A). The function of
the batteries should basically only be to start
the truck. Before changing the size of the alternator, read Changing the alternator.

90

1 Add together the power consumed by all

the loads in the vehicle which can be
simultaneously connected when the vehicle is being driven (see table below). Add
the charge excess (at least 10 A).

50

80
70
60

40

65 A

30
20
10

2 Determine which type of driving is appropriate. Long-haul vehicles generally stop

less often and can therefore have a smaller
alternator than vehicles which often stop.
Use the chart to the right to see which
alternator size is required.

Electrical load

90 A

Long-haul truck. Truck with regular stops.

Example: If consumption is 40 A, you must
size for 50 A. If the vehicle is a long-haul
truck, a 65 A alternator will suffice. A delivery
truck will require a 90 A alternator.

Amperes/unit

Quantity

Total

18-23

ABS

0.5

EDC

3.5

Opticruise

0.5

Extra lights

0.5

Roof lighting

Load lamps

Heated seat

Heated mirrors

Cab heater

Battery heater

1.5

Rear light

0.5

Side marker lights

0.5

Width marking light

0.25

Cabinet illumination

0.5

Truck standard

Side marker lights

Radio
Cabinet illumination

18-23

Trailer

ABS
Miscellaneous (see remarks for each option)

=
Total consumption =

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Scania CV AB 1996

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Alternator

Alternator current at ratio 3.5:1

The current generated by the alternator is dependent on engine speed. The table shows the current
supplied by the alternator at various engine speeds.
Engine
(rpm)
500
600
700
800
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400

Alternator
(rpm)
1750
2100
2450
2800

Alternator current
90 A
42
58
69
76

3150
3500
3850
4200
4550
4900
5250
5600
5950
6300
6650
7000
7350
7700
8050
8400

80
83
86
88
89
90
91
92
93
94
94
94
95
95
96
96

65 A
31
40
46
50
53
56
58
60
61
63
64
64
65
65
66
66
67
67
67
67

Frequency
The output frequency (f) at connection W is
calculated using the alternator speed (rpm) and
number of poles:
f=

No. of poles x rpm

60

90 A = 8 poles
65 A = 6 poles

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Example: Frequency at e.g. 3500 rpm for a

65 A alternator (6-pole):
f=

6 x 3500
60

= 350 Hz

The output frequency at W is 350 Hz for a

6-pole alternator at 3500 rpm.

Scania CV AB 1996

15

Fault diagnosis

Fault diagnosis
SYMPTOM

SUGGESTED
REMEDIAL MEASURE

1 Battery fault.

Check the specific gravity of

the electrolyte and test for
short-circuit.

2 Alternator belt slipping.

Check with charge test.

3 Regulator fault
(providing too low
system voltage).

Check with charge test.

Tachometer also twitchy.

4 Alternator fault (phase

fault).

Change the alternator.

No reading on ammeter.

5 Voltage drop or break in

circuit for B+.

Measure voltage drop

between B+ and battery+.

The charge lamp remains on,

even when the engine is
running.

1 Alternator belt slipping

or broken.

Check the drive belt.

2 Circuit for D+ is
earthed.

Check the circuit.

Starting difficulties

A1

Charge lamp indication is

normal, both with engine
off and engine running.

A2

16

PROBABLE CAUSE

Will cause starting difficulties in the long-term

B1

The charge lamp is on when

the ignition is switched on,
but is dimly lit when the
engine is running.

1 Contact resistance to
the lamp or to earth in
the alternator.

B2

The charge lamp also lights

at high engine speed.

1 See symptom A2.

Scania CV AB 1996

Measure the circuits and

repair.

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Fault diagnosis

Fault diagnosis (continued)

SYMPTOM

PROBABLE CAUSE

SUGGESTED
REMEDIAL MEASURE

The charge lamp does not

light when the ignition is
switched on. (Engine off).

1 Break in circuit to D+.

Check the circuit (connect the

cable for D+ at the alternator
to earth).

2 The brushes are worn.

Check the brushes and slip

rings.

3 Break in field circuit.

Measure resistance in rotor

winding.

4 Break in regulator (not

providing earth).

Check the regulator.

B3.1 Special case:

5 Lamp is blown.

Check and change the lamp.

B4

Control voltage is too high

during control voltage test.

1 Fault in regulator.

Conduct charge test.

All cells in battery boil dry.

2 Contact resistance in
regulators earthing
point to alternator
casing.

Remove the regulator and

test it.

3 Contact resistance
between B- and
alternator casing.

Test using a multimeter.

4 Short circuit in battery.

Check the batteries.

B3

A few of the batterys cells

are boiling dry.

Work after fault diagnosis / repair

Some of the vehicles control units may have generated fault codes, either due to the fault or during
the fault diagnosis. Do not forget to check and erase the fault codes, using SD2 if possible.

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Scania CV AB 1996

17

Fault diagnosis

Charge testing

5
D+

Alternators should not be run without a battery

connected as the rectifiers can be overloaded
and destroyed.

W
B
B+

Output test
1 Connect the calibrated test instrument with
the load resistor as illustrated.

2 Start the engine and allow it to run for a

minute or so before conducting the test.
3 Rev the engine to 1715 rpm (6000 rpm for
the alternator) and provide a load using the
load resistor as below.

1
7

The voltmeter should show 28 V.

The alternator should show at least the following currents:

88 A for 90 A
65 A for 65 A

6
101121

4 A digital clamp ammeter can be connected

at B+ on the alternator for more accurate
reading.

1 Test instrument (with voltmeter, ammeter

and load resistor) for alternators.
2 Connection to load resistor.
3 Clamp for current measurement.
4 Connection to voltmeter.
5 Alternator.
6 Starter motor.
7 Battery.

Control voltage test

This test requires fully-charged batteries to
give an accurate result.
1 Connect the voltmeter and ammeter as
illustrated.
2 Start the engine and let it run until the
alternator provides max. 5 A at B+.
3 Rev the engine to 1715 rpm (6000 rpm for
the alternator).
The control voltage at 20 C should be
28.0 V 0.5 V.

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Scania CV AB 1996

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Changing the alternator

Work description
Changing the alternator
When changing to an alternator type with a different number of poles (e.g. 65 A with 6 poles,
or 90 A with 8 poles), the output frequency at
W will change. Certain frequency-dependent
systems must therefore be adjusted:
The exhaust brake and retarder: See
group 10, Brakes.

The combined instrument (O1): Move the

bridging plug on the rear of the instrument
to the position with the correct number of
poles. See group 16, Electrical components.

102027

Rear of combined instrument.

Location of the bridging plug for 8-pole and
6-pole alternators.

2-pole ADR
In trucks with 2-pole ADR, the pole stud for
B- is isolated from the alternators casing. If
the alternator in this type of truck is changed, it
must be replaced with a new one where B- is
isolated from the casing.
Cable terminals
Always change to cable terminals of the same
size. Note that the terminals are coded to prevent them being switched.

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Scania CV AB 1996

19

Brush length / Rotor

Brush length
The brush holder is attached to the charge regulator. The brushes should be checked to see
that their length is correct and that they are not
damaged. The ends should be shiny and
rounded to match the slip rings.
Brush length is measured between the end and
the holder.

101550

For 65 A it should be > 5 mm.

For 90 A it should be > 2.5 mm.

Rotor
Slip rings
The slip rings should show an even, metallic
shine over their entire surface. If they are not
shiny, this indicates poor contact with the
brushes. The slip rings are accessed by removing the charge regulator.
Resistance

For 65 A it should be about 8.4 0.4 .

For 90 A it should be 11.2 .
When measuring seepage between the slip
rings and casing, the ohmmeter should show
infinite resistance (at least 10 M).

20

Scania CV AB 1996

101 591

Rotor resistance is measured using an ohmmeter between the slip rings.

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Stator

Stator
F

In order to gain access to measure the resistance in the stator, the alternator must be
screwed apart and the stators connections to
the diode bridge must be unsoldered. Protect
the diodes against heat by using pliers as a heat
sink.

The resistance between phases should be:

101589

90 A, Phase - Phase: 0.085 .

65 A, Phase - Phase / Phase - Neutral:
approx. 0.3 .

Stator connections, 90 A alternator

F = Phase lead

When measuring seepage between the rotor

windings and casing, the ohmmeter should
show infinite resistance (several M).

101554

Stator connections, 65 A alternator

F = Phase lead
0 = Neutral lead

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Scania CV AB 1996

21

Diodes

Diodes
IMPORTANT! The rectifier diodes are zener
diodes and must not be replaced with any other
type.

Diode
The function of a diode is to release current in
one direction (low voltage drop) and to block it
in the other direction (high voltage drop).
The diode only allows current through in the
direction of the arrow

Zener diode
The particular feature of a zener diode is that it
has a breakdown point at about 54 V where it
begins to release voltage in the blocked direction.
The rectifier diodes are of zener type which
means that if the regulator breaks or if a battery
lead is detached (or becomes loose) when the
engine is running, the alternator still stops
charging at 54 V.

54 V
A zener diode will allow voltage in the reverse
direction at about 54 V

The alternator is thus equipped with overvoltage protection.

22

Scania CV AB 1996

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Diodes

Diodes are most easily checked using a multimeter with a diode test. The diode must be
tested in both directions to ascertain whether it
is intact.

101553

Diode test
W

B+

D+

The voltage drop across a diode should be

between 0.40 and 0.70 V.

2
F

Measure the voltage drop between B+ and each

of the stators connection points (F or F and 0)
to the diode bridge.

101590

+ Diodes (1)

Diode bridge 90 A

- Diodes (2)
Measure the voltage drop between B- and each
of the stators connection points (F or F and 0)
to the diode bridge.

B+

D+

Field diodes (3)

2
F

101553

Measure the voltage drop between D+ and

each of the phases connection points (F) to the
diode bridge.

Diode bridge 65 A

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Scania CV AB 1996

23

Specifications

Specifications
Batteries
Quantity
Ground connection
System voltage
Battery capacity
Specific gravity of electrolyte at 20 C
Lowest specific gravity at 20 C
Charging current
Electrolyte level

Alternator
Designation
Output at 6000 rpm
Ratio
No. of poles
Resistance in rotor
Resistance in stator (phase-phase)
Brushes, min. length
Slip rings, min. diameter
Tightening torque, pulley
Output test
Alternator speed
Engine speed
Min. current
Min. voltage
Control voltage test
Alternator speed
Engine speed
Voltage at + (alternator)
Alternator load
Ambient temperature

Two 12 V connected in series

Negative
24 V
135 Ah, 170 Ah, 180 Ah
1.28 (fully charged batteries)
1.24 (20 % discharged batteries)
10 % of capacity
To the upper edge of the plastic ring in the fixture

65 A, Bosch
N1-28V 20/65A
1800 W
3.5:1
6
approx. 8.4
0.3
> 5 mm
> 26.8 mm
65 Nm

90 A, Valeo
A14VI19
2500 W
3.5:1
8
11.2 5 %
0.085 0.001
> 2.5 mm
> 13.8 mm 0.1
65 Nm

6000 rpm
1715 rpm
65 A
28 V

6000 rpm
1715 rpm
88 A
27 V

6000 rpm
1715 rpm
28 V 0.5 V
max. 5 A
+20 C

6000 rpm
1715 rpm
28 V 0.5 V
max. 5 A
+20 C

Connection diagram Basic electrical system, frame and engine 16:02-03.

24

Scania CV AB 1996

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