Manual Electricidad Automotriz 246o6k

ServiceManual

Section3 (32) Chargingsystem

o

Faulttracing

240, 260 1975-19. .

TP 3072911 3000.03.85 in U.S.A. Printed We reservelhe right to makearteralions O 1984.VOLVOOF AMERICA CORPOBATION

ChargingSystemFaultTracing - 19. . 24O126O;1975

Contents Op6ration

Test equipmentand systemdescription Test equipment Suggestedequipment The charging system, brief description

Page

2 4 5

Fault tracing Faulttracing T h ed o n t so f f a u l t r a c i n g. . . . . . . . . . . . . . . . . . . . . . . . . . . Ouickcheck pre-checks A. Mandatorytroubleshooting Batterytesling . .s. . . . . . . . . . . . . . . . . . . . . . B . B a r t e rt ye s t i n p grocedure Faulttracingchan Faulttracingprocedures, chargingsystem patterns,...,,..,.....,,.,,,... Alternato s cr o p e

10 11 81 -86

c1- c12

14 16 17 24

System specificationsand battery charging Wiring dragrams A l t e r n a t osrp e c i f i c a t i o n. s, . . . . . . . . . . . . , . . . . , , . . , , , . , Transistor voltage regulator, specifications Charginga battery D i o d e k i l. . . . . . . . . . . .

Or.lornumborrP 3O?29-l We reservethe right to makeallerations withoutprior notilication.

37

Group32 Fauhtrccing fest equipment

Test equipment

Marquette 42-130volts ampere tester, SunVat40 volts ampere tester (or equivalent)

@

@

The unit containsa voltmeter,ammeter,built-in carbon pile resistor, and a diode/stator tester. When usingthis equipmentor similarequipment, follow the manufacturer's instructions,

Digital multimeter (Volvo 9996525-3, 80228 or equivalent)

Fluke

Usedto measurecurrent,voltageand resistance, :To take resistancereadingsproperly, the circuit beang tested must be electrically disconnected from adjacent circuits and voltage should not be Dresent,

Gtoup 32 Fault tracing

.J

Test light Used to check for current drain or to checkfor voltagepresentin a circuit.Test light glowswhen approximately 150 milliamperesflow rhroughthe light (the amountoI currentneededto illuminate the test light variesbetweentest lights;150 milliamperesis approximate.)

133 427

fF

tr tr +

lI

+ TI TI E

t+

Hydrometer with thermometer (Volvo 998501 1-7, Snap-On BB4A or equivalent) The hydrometeris used to measurethe specific gravity of the electrolytein bartery cells. This measurementgivesan indicationof the battery's stateof charge.

TI

U

o s\ss

Low-amperagecharger {Marquette Model 30136, Schumaker43141 or equivalent) Recharges 6 and 12 volt batteriesin 3 to 7 hours. Slow chargeof 6 amps preventsbatterydamage causedby overheating.

Group32 Faulttrccing Testequipment

Suggestedequipment This equipmentis stronglyrecommended.

[]fl o o o

o80

0

0

Oscilloscope(automotivol Givesa visualindicationof the alternatoroutDut. Can be usedto quicklyanalyzealternatorfaults. instructionsorovidedwith Referto manufacturer's of normalandabnormalscope the unit.(Examples patternsare includedin Specilications Soction.)

Gtoup 32 Fault tracing

Chargingsystem,brief description

NOTE Drawing to the left is only representative of charging sv5le-ns n general. Refer to speci licationsfor specificwiring diagrams.

Regulator

Thechargingsystemconsistsof threecomponents, the alternator,battery,and voltageregulator. A) Alternator Convertsthe rotarymotionof the engineintoan electricalcurrent.Thereare two generaltypes ol alternatorsusedon Volvos.One type usesan external regulatorand the other an integral (built'in)regulator.Shown is a repfesentative drawingof an alternatorwirh integralregulator. B) Battery Storesan electricalchargefor startingthe car. The battery also helps smooth out voltage fluctuations. Thereare three typesof batteries, standard,low maintenance,and maintenance

133322 integralregulator

Group32 Faulttrccing Components

Standardbatterv Water needs to be added Deriodicallv. May emit significantamountsof gas.

Low-maintenanca (Volvo presendy equips cars with low'maintenance batteries only) -

-

Never needs water added undernormal conditions. Check level at normal servicesorat least Reducedgassing. Low self-discharge.

12t 522

(Volvodoes not presentlyuse Maintenance-freo maintenance-free batteries) No vent plugs. Water cannot be added. Very little gassing.

l. Group 32 Fault tracing

C) Voltage regulators SEV externalregulator

Externaltransistorregulator -

Regulatesby solid state electronics. No movingparts. Relivable, can withstandvibration. Canbe mountedon the alternatoras an integral regulator,

Boschexternalregulator

Inlegralregulator -

Transistortype regulator mounted on the alternator. Compact.

134 543

lntegralregulator

1 3 52 8 8

Integralregulator

NOTE The regulatedvoltagevarieswith the tempera, ture of the regulator.As the temperatureof the regulator increases, the regulated vohage decreases. On some 1985 and latermodels,the regulatoris connectedto a temperaturesensor locatedbeneaththe batterytray;thus,the regu lated voltageis more preciselymatchedto the systern'simmediaterequirements.

Group 32 Fault tftcing Don'ts of fault tracing

Geneml

Faulttracing

0

This section explains theJault tracing method ofcorrecting charging system de{ects. Alllaulttracing must be done in the sequence prcsented in this section. "Short-cut" methods undermine theelliciency ofthe fault tracing method. FIRST Trogbleshooting Prc-checks then Battery Testing

Charging System Fault Tracing

The don'ts of fault tracing When testingor servicingan alternator, avoiddamagingthe unit and its regulatorby carefullyobservingthe followingprecautions:

o A) Neverdisconnect batterycablesor thewiresto the requlatorcables whrle the engine is running.

8) Never reverse battery connections. Check the battery polarity with a voltmeter before making connecrrons rf ihe polarirysigns"-" or "-" are not visible on the battery case.

r I

I Group 32 Fault trccing Don'ts ol lault tracing

o C) Disconnect the batterycablesbeforehookingup a fastcharger,Neverusea fast chargeras a booster lor startingthecar. Do notchargebatterywith battery installedin car; gassingcandamagethe paint.

(D+,/6t ) D) Avoid grounding the field circuit (D+,/61) between the alternator and the regulator, Groundingthe fieldof eitheralternatoror regu, lator may damagethe regulator.

E) Don'tgroundthe alternatoroutputterminal(B+i as this may damagethe alternator,the circuit, or both.This precautionmust be followedeven when the system is not operating,becausethe orrtputterminalon the alternatoris "hot" at all times. Terminalsmust be coveredwith insulatingbootsor tape,

F) Never leave the ignition switch "ON when servicingthe regulator.

o

Group 32 Fauh tracing

Ouick check forthe Fault withFaultTracingTable:Donol u6ethistableasa substitute TabletobeusedONLYin conjunction TracingTablel Fault

Batterynot beingchargedor not being sufficientlycharged.

o

ProbableCause

Currentdrain

Batteryfault

Alternatorfault

0)

Regulatorfault

V belt loose

Chargingsystemoverload

Wiring fault

Frequentshort trips lsee A1 on followingpage)

Alternatorwarning lamp not lit up with engineOFFand ignitionswitch in ON position.

O)

Warninglamp defective

fr Wiring fault

Alternatorwarning lamp glows dimly or flasheswhen engineis running. Faultybatteryconneclion

Regulatorfault

Alternatorfault

Wiring fault, loosefuse

Gtoup 32 Fault tracing Ttoubleshootingprc-checks

pre-checks A. Mandatorytroubleshooting AI Vehicleoperation Analyze the operation of the vehicle. Some problems(e.9.,partially-drained battery)may be the result of excessivestrain on the charging system. Be aware that frequent trips of short durationconstitutea severedriving condition.lf this type of usage characterizesthe vehicle's operation and charging system fault tracing procedures do not revealanyfaults,then {on 1980 and earliermodels)the installationof a 'diodekit" (see last section of manual) may correct the

A2 Check for current drain

129126

A shortin the wiring or electricalequipmentwhich remainson* when the ignition is off, drainsthe battery. Open the circuit at the negative( ) battery post and connecta test light in series.Glowingof test light indicatesa currentdrain.lf thereis a cuF rent d.ain, isoldlethe faulry circuit by removing fuses one at a time until the currentdrain stops. Then continue isolatingthe problemby disconnecting the wires attached to the affected fuse. After isolalingthe faulty circuit,trace the circuit wiring until the fault is lound. Use appropriate wiring diagrams.Proceedto 43. *NOTE:Be aware that car's clock,or iljuminated domelight,etc.maycausesometest lightstoglow.

A3 Check V-belt tension

DEFLECTION

Theperlormance of the alternator, the lifeolthealternator bearings,and the lifeof the V-beltdependsheavily on rnaintaining the correci belt tension.Measurelhe tensionby firmlypressingdown on tne alternatorbelt rnrdwaybetwenlwo pulleysas shown.The beltshould move5/16in.(8mm).Adjustasrequired.Proceedto A4.

NOTE Replace beltsin sets(whereapplicable). NOTE Make sure that instrument WARNING l i g h ti s o n w h e nk e yi s i n " O N ' p o s r t r o(ne n g i n e not running) lf not, refer to C4.

Check systems closely related to the charging

o

Poor engine performanceor a faulty startermay cause what appearto be chargingsystemprob lems.Eliminatepoorengineperformance or starter faults as source(s) of the problem.Proceedto Bat tery Testing.

Group 32 Fault tracing Battery testing

BatteryTesting Gen6rrl Lackof electrolytecausesprematurefailurc oI bafterieslaster than annhing else.Fill batterywithdistilled A water;neverwith acid.Useonlydistilledwater,batterylife isextendedby usingthe purcstwateravailable. dirty batteryshouldbe removedand scrubbodwith a bakingsodaand walor solutionto neutralizeany acid present,(Ona dirtybatterytheremaybecurrentdrainbetlveentheterminals.)Cautionr Besureventcapsare tight so no solutiongets into cellsto neutralizethe acid.Flushbatterywith cleanwater.

WARNING Wear safety glasseswhen working near batteries, All automotivobattari€sgenoratehydrog€ngas which i6 highlyllammable,lf ignited by a sparkor flame, the gas may explodeviotentlycausingsprayingof acid,f.agmentationot the battery,andpossibleseverepersonaliniuries,panicularly to the eyes. Avoid wilh battery acid. In case ol conact, llush affectedareaimmediatelywith waler, and consulta physician.(NOTE:Consult Owner's Manualfor correctjump-startingprocedure.) Chargobattoriosonly in a well-ventilatedarea.Alwaysbe surebattorychargers are "OFF" when connecting-loor disconnocting-lrombatteries. All batterytests must be done in the sequencepresentedin th€ BatteryTesting Chart (n6xt pagel. Always disconnectthe negative(-) battery cable{irst.

Group32 Faulttrccing Battery testing

Batterytesting chart {APPLIESTO STANDARD,LOW.MAINTENANCE, AND MAINTENANCE-FREE BATTERIES)

CHECKFOR PROPER TESTCONDIIIONS, R € F € RT O 8 1 .

. NOTEI 81 TO 86 REFER TO PROCEDURES WHICHFOLLOW.

CHECKFORVISUAL DAMAGE.REFERTO 82.

WHICHTYPEOF BATTERYIS BEING TESTED?

MAINTENANCE-FRE€

CHECKIHE ELECTBOLYTE'S SPECIFICGRAVITY, REFESTO 84. 50 POINTSAETWEENCELLS B E L O W1 2 2 5

LOAD TEST.FEFERTO 85. ABOVE9.6 VOLIS

BELOW9,6 VOLTS PAOCEED TO FAULT TRACING,2-5

BATT€RYGOOD. NECHARGE TO '1260.

PERFORM 3-MINUTESULPHATION TEST. REFERTO 86. AEOVE15.5 VOLTS

BELOW15.5 VOLTS

R E C H A R GTEO 1 2 2 5 OR ABOV€.

TESTAGAIN FROM*.

Group32 Fault tracing Battery testing

B. Batterytesting procedures

BI Checkbatterytest conditions Thebatterymustbeclean.Thebatterytemperature mustbebetween600and100oF(1socand30oC), allowthe batterytemperature to normalizein order to makeaccuratetests.Proceedto 82.

129125

Visual inspection Examine the battery tor the following and correct where applicable: -

Battery rating incorrectfor vehicle require-

-

Wet or dirty case, Low electrotyte levels. Dirty or loose connections, Bent, loose, or broken posts. Crackedcase. Oiny or brown coloaedelectrolyte. Battery not securely held in place {loose hold-

-

A) Maintenance free batteries - proceed to 83 B) Standard or low mainlenance baileries Proceedto 84.

BattedeB Maintenance-free batteries lack filler caps. The battery is sealedexcepltor smallvent holes.Check batteryaccording to manulacturer's specilications,

Group 32 Fault lrccing Battery testing Check the speci{ic gravity

B4

Use a temperature compensatinghydrometer (Refer to manufacturer'sinstructions). Add to the hydrometerreading four gravity points (o.o04ifor each 10oF(5.5oc)that the ambienttemperatureis above80oF(27oC). Subtractfour gravity points (O.OO4) for each 10oF(5.5oC)that the ambienttemperatureis below80oF(27oC). A) Morethan 50 pointsbetweenhighesrand lowest cells -- replacebattery8) Specificgravityabove1225

proceedto 85.

C) Specificgravitybelow 1225 -- proceedto 86. 1 3 04 8 8

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B5 Load test Determinethe amp'hour rating of the battery beingtested. Multiplytheamphourratingtimes3. Thisis the loadcurrentrequiredfor testing.(Loadcurrent required for lesting can also be found by dividingthe "cold-cranking"ampereratingby

12V

_tl

Engine type 4 cylindergas 6 cylindergas Diesel

2.1

Battery rating

NOTE lf Amp,/hourratingcannotbe found,usecharts at left to determinebatteryrating-

60 Amp./hour 70 Amp,/hour 88 Amp,/hour -

Battery cold-cranking Amp rating 360 450 600

Equivalent Amp/hour raling 60 Amp,/hour 70 Amp/hour 88 Amp/hour

Attach a load lcarbonpile resistoror variable high-ratebatterydischarger) acrossthe battery terminalsfor 15 seconds. Observethe voltmeter:

A) Above9.6 volts - batteryis good rechargeand ptoceedlo lhF chatg,ngsvstemfault tracing B) Eelow 9.6 volts - proceedto 86.

B6 Thfee-minute charge test The three minute charge test checks for a sulphated battery. -

I

Ouick charge the battery at 40 amps for 3 minutes. Checkthe voltageacrossthe banerytenninals, with charger"ON."

A) Above 15.5 volts slow chargefor 20 hrs to reversea possible"sulphation"condition;test agarn. Below15.5volts- rechargeand proceedto the chargingsystemfault tracingchart.

Gtoup 32 Fault tftcing

Faulttracingchart,chargingsystem

LOADALT, TO 12 VOLTS.

ALI. INDICATOF. CHECKDASHBOARO ENGINE ON. FEFFNIO C4.

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( VOLTAGE. CHFC(THE CHARGING

ANO LAIEF WIH GASOLINE EICEPTIURBOSi ENGINES.

j,

ALIERNATOR) ALTERNATOFI

0

Gtoup 32 Fault trccing

Fault tracing procedures,chargingsystem OperationsC1 to C12 Before testing Troubleshooting prechecks A1 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 procedures listed here.

cl Charging voltage, alternator unloaded -

li. lr

-

I

Run engineat 2,000 rpm. No accessoryelectricalequipmenton. Connect a voltmeter across the battery terminalsas shown. Observethe vohage.

,1 i I

1 3 04 7 8

o 11

Group32 Fauhtrccing

c2 Charging voltage, regulator disconnected -

Turn ofl ignition(keyat position0). Disconnectthe harnessat the regulator. Attach a voltmeter across the battery. With engine running at approximately2OOO rpm observethe voltage.

(

0 AMMETER

c3 Check amperage, alternator loaded -

Opencircuitat B+ batteryterminal. Installan ammeterand voltmeleras shown. Placea load on the alternatoruntil voltmeter reads 12 volrs.{Usethe Sun Vat-4Oor equivalent carbonpile resistorto loadthe ahernator,) Recordthe amperage(A)-

0

Comparemeasuredreadingwith readingson fault tracingchart.

0, 18

Gloup 32 Fault trccing

c4 Check warning lights

' i t" 35-.\ 'i-------i/. 4

-

EngineON Observethe alternatorwarning lamp Note:Otherwarninglampsmay be illuminated at the same time due to the design of the

-

ls the alternatorwarning lamp on?

'

-65 '- ftrdndrdf 'o'

$-fry,'" 0ffi85

c

TURBOMODELSAND PRE-82 WITHGASOLINEENGINE

C5-C7serveas an explanation ofthe methodsused to determinecorrectchargingsystemoutput(see ChargingSystemFaultTracingChart).

c5 All Turbo Models, and Pre-1982 Models with gasolineengines

o ALTERNATOR

On these models the current used to operatethe fuel pumps is drawn directlyfrom the alternator. Thus, on these models, it is not possible to read total alternatoroutput at the battery.The output measured at the battery, then, will reflect total alternatoroutput minus the current necessaryto operatethe fuel pumps. NOTE The output specificationsgiven in the fault tracing chart have been adjLrstedto reflect the above factors,

0 1 3 33 9 7

Group32 Faulttrccing

DIESELMODELSAND 1982 AND LATER WITHGASOLINEENGINES

c6

Diesel Models and '1982 and later models with gasoline engines

On these models, the total alternator outDutcan be read at the batterv, i.e., on these models the current needed io operatethe tuel pumps is includedin the currentoutput measuredat the battery. Thus, the correct output specifications given in the fault tracingchart are higher than thosefor the modelsdescribedin C5.

/1

I

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ALTERNATOR Comparison oI measured and rated outputs -

c7

Refertothefaulttracingchartandfindthe aher, nator's correct output (as measured at the batery). - ls the measuredoutputwithin the rangegiven on the chart?

c( en (

I

20

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Group 32 Fault tracing

C8 Check alternator,using test brush holder

I

o

-

Connecra volrnelcr acrossthe battery RemoveregLrlator. Installtest brush holder.

Test brush holder CAUTION Do not allowvohageto exceedl6volts; damage to the car may result.

0 Check voltage drops

C9

PositiveCircuitTest Connecta voltmeteracrossthe alternatorB+ terrninaland the battery'spositive(+)terminal. Run eng ne at 2,0OOrpm. Load the alternator by turning on electrical equipmentsuchas headlights, fan,andwindow

o

Observethe vohrneter.

I I

c 21

Gtoup 32 Fauh tracing Fauft tftcing NegativeCircuitTest -

Connecta voltmeteras shown. Run engineat 2,000 mm. Load the alternatorby turning on electrical equipmentsuchas headlights.lan, andwindow defroster,etc. - Observelhe voltmeter,

Eliminato(reduco)voltagadrops

cro

- lf n€cessary scrapeandcleanbatteryterminals. - Tightenbatteryconnections. - Checkground leadsbetweenbattery,engine, and body. - CheckB+terminalson stanerand alternator. Repairor replaceleadsas necessaryso that the positivevoltagedropsare lessthan .3 andnegative voltagedropsaro lessthan .2 volts.

22

Group 32 Fault tracing Fauh tracing

Full fielding test, external regulators

O

ctl

NOTE: This test serves to distinguish between alternatorfaults and regulatorfaults. Turn ignitionOFF.(Keyat position"0.')

-

Disconnect the regulatorwire harnessf romthe regulator. Connecta jumperwire from the D+ terminalto the DF terminal. Connect a voltmeter across the alternator B+ terminaland ground. Start and run engineat 2,0OOrpm. Observethe voltage.

0

I t-! 1$ .'\

:

-

.1:

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ct2 Alternator wiring hamess test (removable harness only) Removeharnessand checkfor shortsor opens with an ohmmeter. Cleanconnectors.

l-I

Gtoup 32 Fault tracing Aftematorscope patterns

i

Alternator scope patterns NOTE must trace measuremeni On Volvos,the oscilloscope betakenlromthe D+/61terminalofthe altemator.Any scopepattems, olher hookupwill resultin misleading whichcouldleadto inconectdiagnoses. NOTE Be awarethat a periodicverticaltrace(of lesser inrensitythan the main horizontaltrace)may 'pattern. This appearas a part of lhe "normal vertical trace is caused by the on'off switching such actionof the regulator.Do not misinterpret a trace as an indicationof an alternatorfault.

Normal

Open diode

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a(

c)( D(

t Shorted diode

24

Group32 Faulttrccing Wiring diagnms

Wiringdiagrams 1975-1976 Group32 ChargingSystem Wiing Diagram1975-1976

Legend: A lgnitionswitch B Fusebox C InstrLrment cluster D Startermotor E Akernator F Voltageregulator

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Group 32 Fault ttacing

1977-197AGroup32 ChargingSystem WiringDiagram1977-197A

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Legeno: C Chargingindicalo.lighl

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,.,

26

Group 32 Fault tracing

1 9 7 9 - 1 9 8 OG r o u p32 Charging Syslem Wirins Diagram 1979-1980

e Leg€nd: B lBtrun€

clu8t6r

G C€picitor NqIE: Th. Yolt.s. rogrd.tor .hown in 3ch.mdic l..ymbolic of lnd not A lolld d!t. rcgulltor 13

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Gtoup32 Fault ttacing Wiing diagrams 1981 Group 32 ChalgingSystem Wiring Diagram1981

Log€nd: I hattunfit du.t6r C bdtbn !$'itd'

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G C€p.dio. |{OTE:Yonlq! ..guLtor $orn In .ch.n.tc lr lnlt rylnDollc ol |clrtl ngdal .olld .t i! r€luLlor b

"-= ,-

f(f'-.: {'

fa

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Group 32 Fault tftcing Whing diagtams

1982 Group 32 ChargingSystem Wiring Diagram1982

Legend: A In.t'|im.nt clult r I lenldon sltch

WW

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Gtoup 32 Fault trccing

1983 Group 32 ChargingSystem Wiring Diagram 1983

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Cq O1

133737

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Group32 Fauhtrccing Wi ng diagtams

1984 Group 32 Cha.gingSystem WiringDiagram1984

c B C D E

Batterychargetailure warning light lgnirion switch Alternator Stader motor

G Cspacitor H Integralregulator

G l2o

KE 8

D

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Group 32 Fault tracing

1985 Group32 ChargingSystem WiringDiagram1985

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Ignition

si.i tch

Liaht on instrument cluster

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461

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Group 32 Fault tBcing

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

Bosch

0120 o120

400 400

756 757

Car 240

1975 Max.amperage Max,wattage Min.Current Outputat 14V

Bosch

o120

912

Car 240

1976-77 Max.amperage Max.wattage Man,Current Outputat 14V

Bosch

0120

932

Car 240

1974-8r Max. amperage Max. wattage Min. Current Outputat 14V

s.E.v.

Marchal

716

02

Car 240

'1978-1981 Max,amperage Max.wattage Min. Current Outputat 14V

o

EnginoType B2OF 55 amps 770 watts Alt. Speed 36A at 2,000 rpm 4OAat 2,350 rpm 55A at 6,000 rpm

EngineType B21A,F 55 amps 770 watts Alt. Speed 36A at 2,000 rpm 47A at 3,0OOrpm 52A at 4,000 rpm

EngineType B21A.F EXCLMPG 55 amps 77Owatts Alt. Speed 36A at 2,000 rpm 47A at 3,000 rpm 52A at 4,0OOrpm

EngineType B21A,F EXCLMPG 55 amps 77Owalts Alt. Speed 36,4at 2,000 rpm 48A al 3,000 rpm 36A at 4,000 rpm

33

Gtoup 32 Fault tracing

Bosch

0120

Car 240

EngineType 8 2 1 F .M P G

1981-

70 amps 980 watts Alt. Speed 30A at 1,500rpm 48A at 2,000rpm 67A at 6,000rpm

I\,4ax. wattage Min. Current Outputat l4V

Bosch

0120 0120

469 469

670

lB2'lF, B23Fl (B23OF)

Car 24O

EngineType 821F (ExclTurbo) 823F, B23OF

1982Max. amperage

-

Min. Current Outputat 14V

-

Bosch

0120

Car 240

1982Max, amperage Max. wattage Min, Current Outpui at 14V

135

s.E.v.

712

Car 260

Marchal

Car 260

=Et\J=F t*^ f:i^

34

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55 amps 770 watts Alt. Speed 35A at 2,000 rpm 48A at 3,000 rpm 53A at 4,000 rpm

EngineType

Min. Current Outplrtat 14V

s .E . v .

EngineType B2'I A, 823E. 821F Turbo

1976-77 Max. ampefage

Marchal

70 amps 980 watts Alt. Speed 464 at 2,000 rpm 58A at 3,000 rpm 64A at 4,000 rpm

1974 Max.amperage Max.wattage Min.Current Outplt at 14V

55 amps 770 watts Alt. Speed 35A at 2,000 rpm 48A at 3,000 rpm 53A at 4,000 rpm

EngineType B27F 55 amps 770 watts Alt. Speed 35A at 2,000rpm 48A at 3,000 rpm 53A al 4,000 rpm

0

Gtoup 32 Fault tracing

s.E.v.

Car 260

Marchal

1979-19a1 Max-amperage Max.wattage Min.Current Outputat 'l4V

Bosch

0120

469

Car 260

1942Max.amperage Max.wattage Min.Current Outputat 14V

Bosch

o120

CaI

260

1980 Max,amperage Max,wattage Min. Current Outputat 14v

Bosch

o120

CaI

260

1981 Max-amperage Max. wattage Min. Current Outputat 14v

Bosch

0120

Cal

260

o

1942Max.amperage Max,wattage Min. Current Outputat 14v

EngineType B2AF. B21F 55 amps 77Owatts Alt. Speed 35A at 2,000 rpm 48A at 3,000 rpm 53A at 4,000 rpm EngineType B2AF 70 amps 980 watts Alt. Speed 464 at 2,000 rpm 58A at 3,000 rpm 64A at 4,000 rpm

EngineType D24 55 amps 770 watts Alt. Speed 36,4at 2,ooo rpm 47A at 3,000 rpm 52A at 4,0OOrpm

EngineType D24 770 watts Alt. Speed 36,4at 2,000 rpm 40A at 2,350rpm 55A at 6,000 rpm

EngineType D24 55 amps 77Owatts Alt. Speed rpm 36A at 2,OOO 47A at 3,000 rpm 52A at 4,000 rpm

Group 32 Fault ttacing

Transistor voltage regulator Specifications Type ........................

B o s c hE F 1 4 V 3 8 o r M a r c h a7l 2 3 1 7 1 0 2

Test conditions Fullychargedbattery T e m p e r a t u raet v o l t a g er e g u l a t o r , . . . . , . . , , . . , . , . . . , . , . , , . . , , . . .

+25oC,

Test values A l t e r n a t osrp e e d . . . . . . . . . . . . . . . . . . . . 6 , 0 0 0r p m Engine speed approx.3,000 rpm . . . 5 ' 1 OA A l t e r n a t ol ro a d VoltagemeasuredacrossterminalsB+ and D- on alternator: Coldvoltageregulator 'l3.7-14.5V (readingwithin 1 min. after starting) Warm voltageregulator (readingafter runningfor 30 min.) 13.5-14.1V

o

Controltolerance 55A alternatorwith 47A (ratingx O.85) 7OA ahernator with 60,4 Controlvohageshould nowbeOtoO.3voklowerthanthepreviousreading. Integral voltage regdlatot Specilications Type e a r l yt y p e . . . . . - . . . . . l a t et y p e . . . . . . . . . . . . .

. . B o s c h0 1 9 2 0 5 2 0 2 7 . . B o s c h1 1 9 7 3 1 1 0 0 8

T e s tc o n d i t i o n s S t a t eo f b a t t e rcyh a r g e Air temperature warmregulator. . . . . . . . ........ Temperature,

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......Incar .................. m i n3 / 4 +25'C {77'F) . . . . . . +60-80'C040-176oF)

Test values 134 543

..................... 6 , 0 0 0r p m A l t e r n a tsopr e e d . . . . . . . . . . . . . . . . . 3 , 0 0 0r p m E n g i nsep e e d . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-504' Alternator load . . . . . . . . Controlvoltage,betweenB+ and D- altemalorteminalsi (reading takenwithin1 mln).. . . . . . . . . . . . . . . . .....14.4-14-BV Cofdregulator 13.8-14.3V w a r mr e g u l a t(orru nm i n i m u 1 m5 m i na t 3 , 0 0 0r p m ) . . . . . . . . . . . . . . Control lolerance LOaO

1352Aa

55Aaltemator to 50A....... 9 0 A. . . . . . . . .

.. ...

. . . . . . . . . . . . . . . . . . . . . . . . 474 . . . . . . . . . . . . . . . . . . . .60A 77A ...................

Thecontrolvoltageshouldnowbe between 0 and0.3voltslowerthanthe prevaous reading, *Loadachieved whenenginerunning

o

tuoup32 Faultvacing Charyinga battery;Diodekit

Charginga battery Check the level of the electrolyte, and iI necessarytop-up with dastilledwater. Charge the bartery for a minimumof 1Ohoursat the recommended chargingcurrent.Themaximumrecommended chargingcurrentis 0.1 x the capacity of the battery. EXAMPLE: Capacityis 60 Ah, recommended maximumchargingcurrentis: O.1x 60 = 64. After charging the battery, measure the specific gravity of the electrolyte in all the cells_The maximum permissibledevialionbetweenthe highestand lowestvaluesmeasuredis 0.03. It is recommendedto always slow-chargea battery.Fast-chargingcausesbatterydamageby overheating.The platesmay warp and bucklewhich can causeseparatordamageand short circuita cell_ Violentbubblingand gasingofthe electrolyte when fast-charging washesrhe activematerialtromthe ptates; this reduces the battery capacity,and can cause internal shons. It sulphation is present,chargeat a lower amperagerate (max.3 AMpS)for a longer period oftime, in order to remove any lead sullate trom the plates, In no casemaysurfatedbatteriesbe fast-chargedat high current rate.Sulfatedbatteriesgasexcessivelyduring initial charging period, therefore, observesalety precautionsouttined in the battery check section (2_4). A chargingtime ol 1O hours at a low currentlevelinsuresthat the batteryis not damagedbythe charging process.lI this is an inconvenientamount of time to have the car inoperable, a substitutebatterymaf b6 installed temporarilv.

Diodekit The Volvo diode kit P/N 75903-5 may be used to raisethe chargingrate.

CAUTION Do not use diode kit if charging voltage is abovethe shadodband in the graph. Installdiodeas shown. Check that system is not overcharging16 15,5 Charging voltage

15 14

-3O-2O-1O o +1O+2O+3O+40150+60 +7o+8O 0C -20 0 0F t2 70 100 130 t5o Ambient 130492

37

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