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ServiceManual

o

Faulttracing

Section3 (32)

Chargingsystem

240, 260

1975-19

TP 3072911

3000.03.85

PrintedinU.S.A.

We reservelhe rightto makearteralions

O 1984.VOLVOOFAMERICACORPOBATION

ChargingSystemFaultTracing

24O126O;1975 - 19

Contents

Op6ration

Testequipmentand systemdescription

Test equipment Suggestedequipment The charging system,brief description

Faulttracing

Faulttracing

Thedontsoffaulttracing

Ouickcheck

A. Mandatorytroubleshootingpre-checks

Batterytesling

B. Barterytestingprocedures

Faulttracingchan

Faulttracingprocedures,chargingsystem

Alternatorscopepatterns,

,,

,

,,.,,,

81 -86

c1 - c12

Systemspecificationsand batterycharging

Wiringdragrams Alternatorspecifications. , Transistorvoltageregulator,specifications Charginga battery Diodekil

,

,

,

,, ,.,

Page

2

4

5

10

11

14

16

17

24

37

Or.lornumborrP 3O?29-l

Wereservethe rightto makeallerations withoutpriornotilication.

Group32 Fauhtrccing

fest equipment

@

@

Testequipment

Marquette 42-130volts ampere tester, SunVat- 40 volts ampere tester (or equivalent)

The unit containsa voltmeter,ammeter,built-in carbon pile resistor,and a diode/stator tester.

When usingthisequipmentor similarequipment, followthe manufacturer'sinstructions,

Digital

multimeter

(Volvo 9996525-3,

80228

or equivalent)

Fluke

Usedto measurecurrent,voltageand resistance, Remember:To take resistancereadingsproperly, the circuit beangtested must be electrically disconnectedfrom adjacent circuits and voltage should not be Dresent,

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133427

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s\ss

fF

tr

tr

l-

+ I

+

TI

TI

t+ E

TI U

Test light

Gtoup 32 Fault tracing

Usedto checkfor currentdrain or to checkfor voltagepresentin a circuit.Testlightglowswhen approximately150 milliamperesflow rhroughthe light(theamountoI currentneededto illuminate the testlightvariesbetweentestlights;150milli- amperesis approximate.)

Hydrometer with thermometer (Volvo 998- 5011-7, Snap-OnBB4A or equivalent)

The hydrometeris usedto measurethe specific

gravity of the electrolytein barterycells. This

measurementgivesan indicationof the battery's

stateof charge.

Low-amperagecharger {Marquette Model 30- 136, Schumaker43141 or equivalent)

Recharges6 and 12 voltbatteriesin 3 to 7 hours. Slow chargeof 6 ampspreventsbatterydamage causedby overheating.

Group32 Faulttrccing Testequipment

Suggestedequipment

Thisequipmentis stronglyrecommended.

o

o

o

[]fl

o80

0

0

Oscilloscope (automotivol

Givesa visualindicationof the alternatoroutDut. Canbe usedto quicklyanalyzealternatorfaults. Referto manufacturer'sinstructionsorovidedwith the unit. (Examplesof normalandabnormalscope patternsareincludedin SpecilicationsSoction.)

Gtoup 32 Fault tracing

Chargingsystem,briefdescription

133322

Regulator

integralregulator

NOTE Drawingto the left is only representativeof chargingsv5le-nsn general.Referto speci licationsfor specificwiringdiagrams.

Thechargingsystemconsistsofthreecomponents, the alternator,battery,andvoltageregulator.

A) Alternator

Convertstherotarymotionoftheengineintoan electricalcurrent.Thereare two generaltypes ol alternatorsusedonVolvos.Onetypeusesan externalregulatorand the other an integral (built'in)regulator.Shown is a repfesentative drawingof analternatorwirhintegralregulator.

B) Battery

Storesan electricalchargefor startingthecar. The batteryalso helps smooth out voltage fluctuations.Therearethreetypesof batteries, standard,low maintenance,and maintenance

Group32 Faulttrccing Components

12t 522

Standardbatterv

Water needsto be addedDeriodicallv. May emit significantamountsof gas.

Low-maintenanca (Volvo presendy equips cars with low'maintenancebatteriesonly)

- Never needswater added undernormalcondi- tions. Checklevelat normal servicesorat least

Reducedgassing.

- Low self-discharge.

Maintenance-freo (Volvodoes not presentlyuse

maintenance-free

batteries)

No vent plugs. Water cannot be added. Very little gassing.

l.

SEVexternalregulator

Boschexternalregulator

134543

135288

lntegralregulator

Integralregulator

C) Voltage regulators

Group 32 Fault tracing

Externaltransistorregulator

- Regulatesby solidstateelectronics. No movingparts. Relivable,canwithstandvibration.

- Canbemountedonthealternatorasanintegral regulator,

Inlegralregulator

- Transistortype regulator mounted on alternator.

- Compact.

the

NOTE The regulatedvoltagevarieswith thetempera,

ture of the regulator.As the temperatureof the

regulator increases,the

regulated vohage

decreases.On some1985andlatermodels,the regulatoris connectedto a temperaturesensor locatedbeneaththebatterytray;thus,the regu

latedvoltageis morepreciselymatchedto the systern'simmediaterequirements.

Group 32 Fault tftcing Don'ts of fault tracing

Geneml

Faulttracing

0

This section explainstheJault tracing method ofcorrecting charging systemde{ects.Alllaulttracing must be done in the sequenceprcsented in this section. "Short-cut" methods underminetheelliciency ofthe fault tracing method.

FIRST

Trogbleshooting Prc-checks

then

Battery Testing

Charging System Fault Tracing

Thedon'ts of fault tracing

Whentestingor servicingan alternator,avoiddamagingthe unitanditsregulatorbycarefullyobservingthe followingprecautions:

A) Neverdisconnectbatterycablesorthewiresto

the

running.

requlatorcableswhrle the engineis

8) Never reverse battery connections.Checkthe batterypolaritywith a voltmeterbeforemaking "-"

are

connecrronsrfihe polarirysigns not visible on the batterycase.

"-"

or

o

I

r

I

o

o

(D+,/6t )

Group 32 Fault trccing Don'ts ol lault tracing

C) Disconnectthebatterycablesbeforehookingup a fastcharger,Neveruseafastchargerasa booster lor startingthecar.Donotchargebatterywithbat- teryinstalledincar;gassingcandamagethepaint.

D) Avoid grounding the field circuit (D+,/61) between the alternator and the regulator, Groundingthefieldof eitheralternatoror regu, latormaydamagethe regulator.

E) Don'tgroundthealternatoroutputterminal(B+i

as this maydamagethe alternator,the circuit, or both.Thisprecautionmustbefollowedeven when the systemis not operating,becausethe

orrtputterminalon the alternatoris

times.Terminalsmust be coveredwith insu-

"hot"

at all

latingbootsor tape,

F) Never leavethe ignitionswitch "ON servicingthe regulator.

when

Group 32 Fauh tracing

Ouickcheck

TabletobeusedONLYinconjunctionwithFaultTracingTable:Donolu6ethistableasasubstitutefortheFault

TracingTablel

Fault

Batterynot beingchargedor not being sufficientlycharged.

Alternatorwarninglampnot lit up with engineOFFand ignitionswitchin ON position.

Alternatorwarninglampglowsdimlyor flasheswhen engineis running.

ProbableCause

Currentdrain

Batteryfault

Alternatorfault

Regulatorfault

V beltloose

Chargingsystemoverload

Wiringfault

Frequentshorttrips lsee A1 on followingpage)

Warninglampdefective

Wiringfault

Faultybatteryconneclion

Regulatorfault

Alternatorfault

Wiringfault,loosefuse

o

0)

O)

fr

Gtoup 32 Fault tracing Ttoubleshootingprc-checks

A. Mandatorytroubleshootingpre-checks

129126

DEFLECTION

o

AI

Vehicleoperation

Analyze the

problems(e.9.,partially-drainedbattery)may be the result of excessivestrain on the charging system.Be aware that frequenttrips of short

durationconstitutea severedrivingcondition.lf this type of usage characterizesthe vehicle's operation and charging system fault tracing

proceduresdo not revealanyfaults,then andearliermodels)the installationof a

operation of

the

vehicle. Some

1980

'diode kit"

{on

(see last section of manual) may correctthe

A2

Checkfor currentdrain

A shortinthewiringorelectricalequipmentwhich

remainson* when the ignitionis off,drainsthe

battery.Openthe circuit at the negative(

postandconnecta testlightin series.Glowingof testlightindicatesa currentdrain.lf thereisa cuF rent d.ain, isoldlethe faulrycircuitby removing fusesone at a time untilthe currentdrainstops. Then continueisolatingthe problemby discon- necting the wires attached to the affected fuse. After isolalingthe faultycircuit,tracethe circuit wiring until the fault is lound. Use appropriate wiringdiagrams.Proceedto 43.

*NOTE: Be awarethat car'sclock,or

domelight,etc.maycausesometestlightstoglow.

)

battery

iljuminated

CheckV-belttension

A3

Theperlormanceofthealternator,thelifeolthealterna-

tor bearings,andthelifeof theV-beltdependsheavily on rnaintainingthe correcibelttension.Measurelhe tensionby firmlypressingdownon tnealternatorbelt rnrdwaybetwenlwo pulleysasshown.Thebeltshould move5/16in.(8mm).Adjustasrequired.Proceedto A4.

NOTE Replacebeltsin sets (whereapplicable).

NOTE

Make sure that instrumentpanelWARNING

lightisonwhenkeyisin "ON

not running) lf not,referto C4.

'posrtron (engine

Check systems closely related to the charging

Poorengineperformanceor a faultystartermay causewhat appearto be chargingsystemprob lems.Eliminatepoorengineperformanceorstarter faultsassource(s)of the problem.Proceedto Bat teryTesting.

Group32 Fault tracing Battery testing

BatteryTesting

Gen6rrl

Lackof electrolytecauses prematurefailurcoI bafterieslasterthanannhingelse.Fillbatterywithdistilled water;neverwith acid.Useonlydistilledwater,batterylifeisextendedbyusingthepurcstwateravailable.A dirtybatteryshouldbe removedandscrubbodwith a bakingsodaandwalorsolutionto neutralizeanyacid present,(Onadirtybatterytheremaybecurrentdrainbetlveentheterminals.)CautionrBesureventcapsare tight so no solutiongetsintocellsto neutralizethe acid.Flushbatterywith cleanwater.

WARNING Wearsafetyglasseswhen workingnearbatteries,

All automotivobattari€sgenoratehydrog€ngaswhich i6 highlyllammable,lf ignitedby a sparkor flame,the gasmayexplodeviotentlycausingsprayingof
acid,f.agmentationotthebattery,andpossibleseverepersonaliniuries,panicu-

larly to the eyes.Avoid contact wilh batteryacid. In caseol conact, llush

affectedareaimmediatelywith waler,andconsultaphysician.(NOTE:Consult

Owner'sManualfor correct

Chargobattoriosonlyin awell-ventilatedarea.Alwaysbesurebattorychargers are "OFF" whenconnecting-loor disconnocting-lrombatteries.

All batterytestsmustbedoneinthe sequencepresentedinth€BatteryTesting

Chart (n6xtpagel.

jump-startingprocedure.)

Alwaysdisconnectthe negative(-)batterycable{irst.

Group32 Faulttrccing Battery testing

Batterytesting chart

{APPLIESTO STANDARD,LOW.MAINTENANCE,AND

MAINTENANCE-FREEBATTERIES)

CHECKFORPROPER TESTCONDIIIONS, R€F€RTO 81.

CHECKFORVISUAL DAMAGE.REFERTO 82.

. NOTE I 81 TO 86 REFER TO PROCEDURES WHICHFOLLOW.

WHICHTYPEOF BATTERYIS BEING TESTED?

MAINTENANCE-FRE€

CHECKIHE ELECTBOLYTE'SSPECIFICGRAVITY, REFESTO 84.

50 POINTSAETWEENCELLS BELOW1225

LOADTEST.FEFERTO 85.

ABOVE9.6 VOLIS

BATT€RYGOOD. '1260. NECHARGETO

BELOW9,6 VOLTS

PAOCEEDTO FAULT

TRACING,2-5

PERFORM3-MINUTESULPHATIONTEST.

REFERTO 86.

AEOVE15.5 VOLTS

BELOW15.5 VOLTS

RECHARGETO 1225 OR ABOV€.

TESTAGAIN

FROM *.

Group32 Fault tracing Batterytesting

B. Batterytestingprocedures

129125

BI

Checkbatterytest conditions

Thebatterymustbeclean.Thebatterytemperature mustbebetween600and100oF(1socand30oC),

allowthebatterytemperaturetonormalizeinorder to makeaccuratetests.Proceedto 82.

Visual inspection

Examinethe batterytor the following and correct whereapplicable:

- Battery rating incorrectfor vehicle require-

Wet or dirty case, Low electrotytelevels.

- Dirty or looseconnections,

- Bent, loose,or broken posts.

- Crackedcase. Oiny or brown coloaedelectrolyte.

- Battery not securely held in place {loose hold-

A) Maintenancefree batteries - proceedto 83

B) Standard or

low

Proceed to 84.

BattedeB

mainlenancebaileries -

Maintenance-freebatteries lack filler caps. The batteryis sealedexcepltor smallvent holes.Check batteryaccordingto manulacturer'sspecilications,

130488

'u

12V

_tl

Engine type

Battery rating

4

cylindergas

60 Amp./hour

6

cylindergas

70 Amp,/hour

Diesel

88 Amp,/hour

Battery

Equivalent

cold-cranking

Amp/hour

Amp rating

raling

360

60Amp,/hour

450

70Amp/hour

600

88 Amp/hour

I

Group 32 Fault lrccing Battery testing

Check the speci{ic gravity

B4

Use a

(Refer to manufacturer'sinstructions).

temperaturecompensatinghydrometer

Add to the hydrometerreadingfour gravity points(o.o04ifor each 10oF(5.5oc)that the ambienttemperatureis above80oF(27oC). Subtractfour gravitypoints(O.OO4)for each 10oF(5.5oC)that the ambienttemperatureis

below80oF(27oC).

A)

Morethan50 pointsbetweenhighesrandlow- estcells -- replacebattery-

8)

Specificgravityabove1225

proceedto 85.

C)

Specificgravitybelow 1225 -- proceedto 86.

Load test

B5

Determinethe amp'hourratingof the battery beingtested.

Multiplytheamphourratingtimes3.Thisisthe

loadcurrentrequiredfor testing.(Loadcurrent

requiredfor

dividingthe

2.1

lesting can also be found by "cold-cranking" ampereratingby

NOTE lf Amp,/hourratingcannotbefound,usecharts at leftto determinebatteryrating-

- Attacha load lcarbon pile resistoror variable high-ratebatterydischarger)acrossthebattery terminalsfor 15 seconds. Observethe voltmeter:

A) Above9.6 volts - batteryis goodrechargeand ptoceedlo lhF chatg,ngsvstemfaulttracing

B) Eelow9.6 volts - proceedto 86.

Thfee-minute charge test

B6

The three minute charge test checks for a sulphatedbattery.

- Ouickchargethe batteryat 40 amps for 3 minutes. Checkthevoltageacrossthe banerytenninals, with charger "ON."

A) Above 15.5volts

slow chargefor 20 hrs to

reversea possible"sulphation" condition;test agarn.

Below15.5volts - rechargeandproceedto the chargingsystemfaulttracingchart.

Gtoup 32 Fault tftcing

Faulttracingchart,chargingsystem

CHFC(THECHARGINGVOLTAGE.

ANOLAIEFWIH GASOLINE ENGINES.EICEPTIURBOSi

ALIERNATOR)

ALTERNATOFI

LOADALT,TO 12 VOLTS.

CHECKDASHBOAROALI. INDICATOF. ENGINEON.FEFFNIO C4.

e (

(

j,

0

Gtoup 32 Fault trccing

Faulttracingprocedures, chargingsystem OperationsC1 to C12

Before testing

Troubleshooting prechecksA1 to A4

Battory tests 8'l to 86 must be corrpleted

NOTE: Consult the "Fault tracing chart" on the previous page prior to following the procedureslisted here.

o

130478

cl

Charging voltage, alternator unloaded

Runengineat 2,000rpm.

- Noaccessoryelectricalequipmenton.

li.

lr

,1

i

I

I

Connect a

terminalsas shown.

voltmeter across the

- Observethe vohage.

battery

Group32 Fauhtrccing

AMMETER

c2

Charging voltage, regulator disconnected

- Turnofl ignition(keyat position0).

- Disconnectthe harnessat the regulator.

Attach a voltmeter acrossthe battery.

- With engine running at approximately2OOO rpm observethe voltage.

c3

0

(

Check amperage, alternator loaded

- Opencircuitat B+batteryterminal.

0

- Installan ammeterandvoltmeleras shown.

- Placea loadon the alternatoruntilvoltmeter reads12 volrs.{Usethe SunVat-4Oor equiva-

lentcarbonpileresistorto loadthe ahernator,)

- Recordthe amperage(A)-

Comparemeasuredreadingwith readingson faulttracingchart.

 

0,

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0

133397

4

' '

35-.\

i

' 'i-------i/.

t"

- ftrdndrdf 'o'

-65

$-fry,'"

0ffi85

TURBOMODELSAND PRE-82 WITHGASOLINEENGINE

ALTERNATOR

Checkwarning lights

Gloup 32 Fault trccing

c4

- EngineON Observethe alternatorwarninglamp Note:Otherwarninglampsmaybeilluminated at the same time due to the designof the

- ls the alternatorwarninglampon?

C5-C7serveasanexplanationofthemethodsused

to determinecorrectchargingsystemoutput(see ChargingSystemFaultTracingChart).

c5

All Turbo Models, and Pre-1982 Modelswith gasolineengines

On these modelsthe current usedto operatethe fuel pumpsis drawn directlyfrom the alternator. Thus, on these models,it is not possibleto read total alternatoroutputat the battery.The output measured at the battery, then, will reflect total alternatoroutputminusthe currentnecessaryto operatethe fuel pumps.

NOTE The output specificationsgiven in the fault tracing chart have been adjLrstedto reflect the abovefactors,

Group32 Faulttrccing

DIESELMODELSAND 1982AND LATER WITHGASOLINEENGINES

ALTERNATOR

20

c6

Diesel Models and '1982 and later models with gasoline engines

On these models,the total alternatoroutDutcan be read at the batterv, i.e.,on these modelsthe current neededio operatethe tuel pumps is includedin the currentoutputmeasuredat the battery. Thus, the correct output specifications givenin the fault tracingchartare higherthan thosefor the modelsdescribedin C5.

c7

Comparison oI measuredand rated outputs

-

Refertothefaulttracingchartandfindtheaher, nator's correct output (as measured at the batery).

/1

I

o(

@(

- ls the measuredoutputwithinthe rangegiven on the chart?

c(

e n

(

I

,i

I

o

0

o

c

Testbrushholder

CAUTION Donotallowvohageto exceedl6volts;damage to the car mayresult.

I

I

Group32 Fault tracing

C8

Checkalternator,usingtest brushholder

- Connecra volrnelcracrossthe battery

- RemoveregLrlator.

- Installtestbrushholder.

Check voltage drops

PositiveCircuitTest

C9

Connecta voltmeteracrossthe alternatorB+ terrninalandthe battery'spositive(+)terminal. Runengne at 2,0OOrpm. Load the alternatorby turning on electrical equipmentsuchasheadlights,fan,andwindow

Observethe vohrneter.

Gtoup32 Fauh tracing Fauft tftcing

NegativeCircuitTest

- Connecta voltmeteras shown.

- Runengineat 2,000 mm.

- Loadthe alternatorby turning on electrical equipmentsuchasheadlights.lan,andwindow defroster,etc.

- Observelhe voltmeter,

cro

Eliminato(reduco)voltagadrops

-

lf n€cessaryscrapeandcleanbatteryterminals.

-

Tightenbatteryconnections.

-

Check groundleadsbetweenbattery,engine,

andbody.

-

CheckB+terminalson stanerandalternator.

Repairor replaceleadsas necessaryso that the

positivevoltagedropsarelessthan

.3andnegative

voltagedropsarolessthan .2 volts.

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:

Group32 Fault tracing

Fauh tracing

ctl

Full fielding test, external regulators

NOTE: This test serves to distinguish between alternatorfaultsandregulatorfaults.

Turn ignitionOFF.(Keyat position"0.')

Disconnectthe regulatorwireharnessfromthe regulator.

- Connecta jumper wire fromthe D+terminalto the DFterminal.

- Connect a voltmeter across the alternator B+ terminalandground.

- Startand run engineat 2,0OOrpm. Observethe voltage.

Alternator

harnessonly)

wiring

hamess test

ct2

(removable

- Removeharnessandcheckfor shortsor opens with an ohmmeter. Cleanconnectors.

Gtoup32 Fault tracing Aftematorscope patterns

Normal

Alternatorscope patterns

NOTE On Volvos,theoscilloscopetracemeasuremenimust

betakenlromtheD+/61terminalofthealtemator.Any

olherhookupwill resultin misleadingscope pattems, whichcouldleadto inconectdiagnoses.

NOTE Beawarethata periodicverticaltrace(oflesser inrensitythan the main horizontaltrace)may

appearas a partof lhe "normal 'pattern. This

verticaltrace is causedby the on'off switching

actionof theregulator.Donotmisinterpretsuch a traceas an indicationof an alternatorfault.

Opendiode

Shorted diode

l- I

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0(

a(

c)

D(

t

Group32 Faulttrccing

Wiring diagnms

Wiringdiagrams

1975-1976Group32 ChargingSystem Wiing Diagram1975-1976

Legend:

A

lgnitionswitch

B

Fusebox

C

InstrLrmentcluster

D

Startermotor

E

Akernator

F

Voltageregulator

^^'

Group 32 Fault ttacing

1977-197AGroup32 ChargingSystem WiringDiagram1977 -197A

Legeno:

C Chargingindicalo.lighl

0

c(

c(

,.,

e

 

Leg€nd:

 

B

lBtrun€

clu8t6r

G

C€picitor

NqIE: Th. Yolt.s. rog-

rd.tor .hown in 3ch.mdic

l ymbolic of lnd not

A lolld d!t.

rcgulltor 13

c

rc

I

Group 32 Fault tracing

1979-198OGroup 32 Charging Syslem Wirins Diagram1979-1980

Gtoup32 Fault ttacing Wiing diagrams

Log€nd:

hattunfit

bdtbn

I

C

du.t6r

!$'itd'

G

C€p.dio.

|{OTE:Yonlq!

$orn In .ch.n.tc lr lnlt rylnDollc ol |clrtl ngda-

guLtor

l

.olld .t

i! r€luLlor b

1981 Group32 ChalgingSystem

WiringDiagram1981

WW

f(f'-.:

,- {'

"-=

fa

lsYl/t

o

o

Legend:

A In.t'|im.nt

clult

r

I lenldon sltch

1982 Group32 ChargingSystem

WiringDiagram1982

Group32 Fault tftcing Whing diagtams

WW

Gtoup 32 Fault trccing

133737

1983 Group32 ChargingSystem

WiringDiagram1983

o

o

@

(

(

Cq

O1

o

B

Batterychargetailure

warninglight

C

lgnirionswitch

D

Alternator

E

Stadermotor

G

Cspacitor

H

Integralregulator

o

1984 Group32 Cha.gingSystem

WiringDiagram1984

G l2o

KE

D

8

Group32 Fauhtrccing

Wi ng diagtams

c

I

Group 32 Fault tracing

Ignition

si.i tch

1985 Group32 ChargingSystem

WiringDiagram1985

Liaht

instrument

on

?'i

a

!

l*"

461

cluster

c(

o(

0r

Soecifications

Group 32 Fault tBcing

3-2 AltematorSpecifications('Specificationsare given{or off-cartestingonly)

Bosch

0120

400

756

Car

EnginoType

o120

400

757

240

1975

B2OF

 

Max.amperage

55amps

Max,wattage

770

watts

Min.Current Outputat 14V

Alt. Speed 36Aat 2,000rpm 4OAat 2,350rpm 55A at 6,000rpm

Bosch

o120

912

Car

EngineType

 

240

1976-77

B21A,F

 

Max.amperage

55

amps

Max.wattage

770

watts

Man,Current Outputat 14V

Alt. Speed 36Aat 2,000rpm 47A at 3,0OOrpm 52A at 4,000rpm

Bosch

0120

932

Car

EngineType

 

240

1974-8r

B21A.F

 

EXCLMPG

 

Max.amperage

55

amps

Max. wattage

77Owatts

Min. Current

Alt. Speed

Outputat 14V

36A at 2,000rpm 47A at 3,000rpm 52Aat 4,0OOrpm

s.E.v.

716

02

Car

EngineType

Marchal

240

'1978-1981

B21A,F

o

EXCLMPG

Max,amperage

55

amps

Max.wattage

77Owalts

Min.Current Outputat 14V

Alt. Speed 36,4at 2,000rpm 48A al 3,000rpm 36Aat 4,000rpm

Gtoup 32 Fault tracing

Bosch

Bosch

Bosch

0120

0120

469

0120

469

670

0120

Car

240

B23Fl

lB2'lF,

(B23OF)

EngineType

1981- 821F.MPG

I\,4ax.wattage

Min. Current

Outputat l4V

Car

24O

1982-

70 amps

980

Alt.Speed 30Aat 1,500rpm 48Aat 2,000rpm 67Aat 6,000rpm

watts

EngineType

821F(ExclTurbo)

 

823F, B23OF

 

Max.amperage

70 amps

 

980

- watts

 

Min. Current

Alt.Speed

Outputat 14V

464

at 2,000rpm

 

58A at 3,000rpm

- 64A at 4,000rpm

Car

EngineType

240

1982-

B2'IA, 823E.

 

821F Turbo

0

 

Max,amperage

55

amps

Max.wattage

770

watts

Min, Current

Alt. Speed

Outpuiat 14V

35A at 2,000rpm

135

48A at 3,000 rpm 53A at 4,000 rpm

s.E.v.

Marchal

s.E.v.

Marchal

712

=Et\J=F

t*^ f:i^

t^'

Car

EngineType

260

1976-77

Max.ampefage

55

amps

770

watts

Min. Current

Alt. Speed

Outplrtat 14V

35A at 2,000 rpm 48A at 3,000rpm 53A at 4,000 rpm

Car

EngineType

260

1974

B27F

Max.amperage Max.wattage Min.Current Outpltat 14V

55amps

770 watts

Alt. Speed 35Aat 2,000rpm 48A at 3,000rpm 53Aal 4,000 rpm

Gtoup 32 Fault tracing

s.E.v.

Car

EngineType

Marchal

260

1979-19a1

B2AF.B21F

 

Max-amperage

55

amps

Max.wattage

77Owatts

Min.Current 'l4V Outputat

Alt. Speed 35A at 2,000rpm 48A at 3,000rpm 53A at 4,000 rpm

Bosch

0120

469

Car

EngineType

 

260

1942-

B2AF

 

Max.amperage

70

amps

Max.wattage

980

watts

Min.Current

Alt.Speed

Outputat 14V

464

at 2,000rpm

 

58Aat 3,000rpm 64Aat 4,000rpm

Bosch

o120

CaI

EngineType

 

260

1980

D24

 

Max,amperage

55

amps

Max,wattage

770

watts

Min.Current Outputat 14v

Alt. Speed 36,4at 2,ooorpm 47A at 3,000rpm 52Aat 4,0OOrpm

Bosch

o120

CaI

EngineType

 

260

1981

D24

o

Bosch

0120

Max-amperage

Max. wattage

770

watts

Min. Current

Alt. Speed

Outputat 14v

36,4at 2,000rpm 40Aat 2,350rpm 55Aat 6,000rpm

Cal

260

1942-

EngineType

D24

Max.amperage

55

amps

Max,wattage

77Owatts

Min.Current Outputat 14v

Alt. Speed 36Aat 2,OOOrpm 47A at 3,000rpm 52Aat 4,000rpm

Group 32 Fault ttacing

Transistor voltage regulator Specifications

Type

BoschEF14V38 or Marchal723 17102

Testconditions

Fullychargedbattery Temperatureat voltageregulator,

Test values

,

,,

,.,

,.,.,,

,,

+25oC,

Alternatorspeed

6,000rpm

Enginespeed

approx.3,000 rpm

Alternatorload VoltagemeasuredacrossterminalsB+and D- on alternator:

Coldvoltageregulator

(readingwithin 1

min. afterstarting)

Warmvoltageregulator (readingafterrunningfor 30 min.)

5'1OA

'l3.7-14.5V

13.5-14.1V

Controltolerance

55A alternatorwith 47A (ratingx O.85) 7OA ahernatorwith 60,4

o

ControlvohageshouldnowbeOtoO.3voklowerthanthepreviousreading.

Integral voltage regdlatot Specilications

Type

earlytype

-

Bosch0192052027

latetype

Bosch1 197311008

Testconditions

Incar

Stateofbatterycharge

min3/4

 

Airtemperature

Testvalues

134543

Alternatorspeed

Enginespeed

.

.

.

.

.

.

.

Alternatorload

.

.

.

.

.

.

.

Controlvoltage,betweenB+ andD- altemalorteminalsi

1352Aa

Cofdregulator(readingtakenwithin1 mln) warmregulator(runminimum15minat 3,000rpm)

.

.

.

.

.

.

.

.

.

.

.

Control lolerance

LOaO

55Aaltematorto

.

.

.

.

.

.

.

.

.

.

50A

.

.

.

.

.

90A

+25'C

{77'F)

+60-80'C 040-176oF)

 

6,000rpm

.

.

.

.3,000rpm

.

.

.

.

.

.

.

.

.

.

.

30-504'

.

.

.

14.4-14-BV

 

13.8-14.3V

.

.

.

.

.

.

.

.

.

.

.

.

.

.

474

.

.

.

.

.

.

.

.

.60A

 

77A

Thecontrolvoltageshouldnowbebetween0 and0.3voltslowerthanthepre- vaousreading,

*Load achievedwhenenginerunning

o

o

tuoup32Faultvacing

Charyinga battery;Diodekit

Charginga battery

Checkthe level of the electrolyte,and iI necessarytop-up with dastilledwater. Chargethe bartery for a minimumof 1Ohoursatthe recommendedchargingcurrent.Themaximumrecommendedchargingcurrentis 0.1 x the capacityof the battery.

EXAMPLE:

Capacityis 60 Ah, recommendedmaximumchargingcurrentis:O.1x 60 = 64.

After charging the battery, measurethe specific gravity of the electrolytein all the cells_The maximum permissibledevialionbetweenthe highestand lowestvaluesmeasuredis 0.03.

It is recommendedto alwaysslow-chargea battery.Fast-chargingcausesbatterydamagebyoverheating.The platesmaywarp and bucklewhich cancauseseparatordamageandshortcircuita cell_

Violentbubblingandgasingofthe electrolytewhenfast-chargingwashesrheactivematerialtromtheptates; this reducesthe battery capacity,and can cause internal shons.

It sulphationis present, chargeat a lower amperagerate (max. 3 AMpS)for a longerperiodoftime, in orderto removeany lead sullate trom the plates,

In nocasemaysurfatedbatteriesbefast-chargedat highcurrentrate.Sulfatedbatteriesgasexcessivelyduring

initial charging period,therefore,observesalety precautions outtined in the battery check section(2_4).

A chargingtime ol 1Ohoursat a low currentlevelinsuresthatthe batteryis notdamagedbythe

process.lI this is an installedtemporarilv.

charging

inconvenientamountof time to havethe car inoperable,a substitutebatterymaf b6

Diodekit

The Volvo diodekit P/N 75903-5 may be usedto raisethe chargingrate.

Charging

voltage

16

15,5

15

14

CAUTION Do not use diode kit if chargingvoltageis abovethe shadodbandin the graph.

Installdiodeas shown. Checkthat system is not overcharging-

-3O-2O-1O o +1O+2O+3O+40150+60+7o+8O 0C

-20

130492

0

t2

70

Ambient

100

130

t5o

0F

o

v0l.v0suPPoRTsvot-ultTRY

tr!ECHAlllCCERTIFIC^Tt0lt

BYTNEil.t.1.S.t.

lUSA only)