Volvo RWD 900 Forum

INDEX FOR 10/2025(CURRENT) INDEX FOR 9/2011 900 INDEX

[<<]  [>>]


THREADED THREADED EXPANDED FLAT PRINT ALL
MESSAGES IN THIS THREAD




  REPLY TO THIS MESSAGE    PRINT   SAVE 

Charging issues 1994 940 Regina 900 1994

Hello all, I haven't had to post for a while.
The charging system in this car is based on the NipponDenso 100 amp alternator. My problem is the battery always discharges and then the car dies. The battery is just 18 months old. I think the battery never gets a full charge from the alternator. The charge voltage is ~13.4 at low speed and high speed. The battery voltage is ~12.4 no load, little change (if any) with load. All connections are clean with no corrosion. The Car has 197,000 miles
I think that the problem lies with the voltage regulator. So, My question is. Does this model Alternator have a replaceable regulator? I can't find one listed on any of my usual internet sources. Otherwise I'll just get a new alternator.

The markings on on the alternator are 3544119 100211-8632

tia
-Keith

[IMG]http://i.imgur.com/3q2P8.jpg[/IMG]








  REPLY TO THIS MESSAGE    PRINT   SAVE 

Charging issues 1994 940 Regina 900 1994

Hi,

Go to Auto Zone and have it checked. It may not be the regulator, worn brushes or a bad diode(s) could be the problem. Replace it with a rebuilt one that has a warranty.

Gus








  REPLY TO THIS MESSAGE    PRINT   SAVE 

Charging issues 1994 940 Regina 900 1994

You can get a voltage regulator for that 100A Denso at eEuroparts.com
These guys are great and sell quality parts at fair prices.

Back to your problem.
The 940 series have a common problem (on the two that I've owned anyway) with faulty solder connections in the instrument panel.
The excitation voltage for the alternator is supplied thru the charge light in the instrument panel. If you have a faulty connection, the alternator will not receive excitation voltage, and will not charge.

This is simple to check.

Does the charge light come on when you turn the ignition switch to "on" position? Does it go off when you start the engine?
It should, and there should be 12V present at the (lone) small (blue I think) wire that plugs into the back of the alternator.
Unplug this wire and check it with a volt meter (without the engine running).
There should be (battery) voltage (to ground) there with the ignition switch turned on.

If there is, and the alternator charges, but is not supplying enough power, the problem could be in the alternator, voltage regulator, or could be as simple as a loose alternator belt.

You say that you have 13.4 Volts with the engine running, and 12.4V at the battery terminals. How are you checking this?
What is the battery voltage with the switch turned off? No load on the battery?

Start the engine and check the voltage at the battery terminals with everything turned on....lights, heater blower, AC, etc.
If the voltage at the battery terminals drops below the 12.4 battery voltage, the alternator is not supplying enough current, and you are draining the battery.
As long as the alternator can supply enough current to keep the battery voltage above 12.4V (or battery voltage whatever it is) with maximum load applied, the alternator is good.

Hope this helps
steve








  REPLY TO THIS MESSAGE    PRINT   SAVE 

Charging issues 1994 940 Regina 900 1994

Steve, Thanks for the tip about eEuroparts. I found a few other sources after that link.

Testing the car. I use a DVM (both auto-rangeing and manual selection) in all tests.
I am aware of the Excitation circuit issues. I read an interesting thread about that somewhere else. That circuit in my car is fine. The excitation wire is colored red in my version. I beeped it out for continuity from the alternator to the (edge card) connector at the back of the cluster. Fine, full continuity, ~0 resistance.
Voltage measures ~13.15 at the alternator end at idle. BATT lamp is lit when key is on, off when running. Although I dont ever remember seeing that BATT light on when this system is failing.

System Voltages:

Battery engine off 12.7v
battery @ idle 750 rpm 13.5v
battery @ ldle loaded 12.3v
battery @ 2000 rpm 12.9v
exciter wire @ idle 13.15v

So clearly these are all low readings. Ill just pull the alternator out and disassemble it. I will then access the condition of the armature (197k miles). I can turn it down on my lathe if it is still in good condition and then just buy a new regulator. OR, Buy a new alternator. Do new alternators come with a regulator installed? I'll most likely get mine from partsgeek.com as they are nearby and they deliver to me very quickly.
thanks again
-Keith








  REPLY TO THIS MESSAGE Replies to this message will be emailed.    PRINT   SAVE 

Charging issues 1994 940 Regina 900 1994

Most new (rebuilt) alternators will come with a regulator pack installed, but these will usually be cheapos, not good ones like Bosch, so don't expect them to last as long or perform as well under extreme conditions.

Your voltage measurement of 13.5 V at idle is okay, but the 12.9 V at 2000 rpm is indeed too low and oddly so what with that idle voltage. In my opinion that would be indicative of a worn alternator, particularly worn bearings coupled with a wear groove in the slip rings. I presume it hasn't been inspected in a few miles so suspect worn brushes as well. Note that with well worn slip rings the minimum brush length should be taken as higher than the 5mm (.2") spec which is why we normally say at least 1/4" -even more if you're going to turn the slip ring surface (I once used just a flat bastard file). Check for fore/aft play in the bearings. There should be virtually none. Note that new bearings spin smoothly, but not freely -spin a new one to feel the difference. Alternator output voltage should really be measured on the terminals on the back of the alternator, between B+ (red cable) and ground (blue cable) as well as D+ (small red) and ground. At 2000 rpm with a fully warmed engine/alternator you're looking for 13.4-14.2 V depending on temperature, electrical load and any resistance in test leads/terminals/wires. First suspect should always be the voltage regulator pack/brushes. Max diff between B+ and D+ is .5 V otherwise suspect bad diodes in the alternator. You should also measure both at the battery and the alternator to determine if there is any voltage drop due to bad cables/contacts (especially ground cabling). Max voltage drop between battery and alternator is supposed to be .25 V. Inspect the blue ground wire on the alternator. The twisted copper wire may become badly corroded, especially if the insulation isn't covering the ends completely. Cable resistance should be near zero Ohms. There are supposed to be two braided ground cables between the valve cover studs and the firewall -make sure they're intact and solidly attached at both ends.

As John suggested, it's not a bad idea to take it to a starter/alternator shop for a test. It's normally free if they smell future business. No matter where you take it, make sure you're getting a "load test".

A few months back I was chasing a mystery battery drain problem. Even died once while stopped for gas. Nary a flicker or glow on the dash alt light. After a jump it would typically be good for the rest of the day. After a bit of chasing I strongly suspected the mildly old (but not ancient) battery couldn't hold a charge. The battery shop tested it as good. I looked for mystery drains by pulling every fuse, but nothing unexpected showed up. As charging voltages both at the alternator and the battery were checking out okay, I had to suspect the alt output amperage. A visual check of the brushes and armature was okay and a shop load tested it at exactly 100 amps. The bearings were starting to get worn, but nothing abnormal. Even though I didn't find a horrible voltage drop across the blue alt ground cable, it was corroded so I subbed a spare and cleaned up all the engine ground contacts including the braided cable between the valve cover studs and the firewall and removed the intake manifold brace for a surface cleaning (both ends). End of problem. The battery simply wasn't getting enough of a charge to hold it for the occasional 7-10 days the car might have sat idle -I was often just using the other 940 as it was often first in line out the driveway and sucks less gas on the highway. I think I didn't spot the voltage drop because I was always testing on dry days and not on damp days where intermittent ground problems can surface.
--
Dave -940's, prev 740/240/140/120 You'd think I'd have learned by now








  REPLY TO THIS MESSAGE Replies to this message will be emailed.    PRINT   SAVE 

Charging issues 1994 940 Regina 900 1994

Charging voltage should be 13.8 to 14.2 volts.

Eventually any alternator will fail as the brushes wear, and get short enough that they no longer touch the slip rings. Most local car parts sellers will do a free alternator check for you.
--
john







<< < > >>



©Jarrod Stenberg 1997-2022. All material except where indicated.


All participants agree to these terms.

Brickboard.com is not affiliated with nor sponsored by AB Volvo, Volvo Car Corporation, Volvo Cars of North America, Inc. or Ford Motor Company. Brickboard.com is a Volvo owner/enthusiast site, similar to a club, and does not intend to pose as an official Volvo site. The official Volvo site can be found here.