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Alternator Not Charging 900 1992

posted by  BrickDad on  Mon Apr 9 10:57 CST 2018
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last visit: Fri Oct 24 10:17 CST 2014
[RELATED]

Started the 92 945T ( nearing 300K miles) this morning to warm up. When I returned to go to the commuter train, I had several warning light on which the FAQ relate to no charging. I checked the voltage at the battery with engine running and sure enough 11.2 Volts=no charging. Having no time to diagnose I shut down, put on the battery charger for as long as I could and did the Apollo 13-like run to the train station successfully.

From the FAQ I get the impression that this could be either:
1. Worn brushes (likely since no alternator issues in the 10 years I've been driving the car or

2. Bad solder joint in the instrument panel leading to no excitation (also likely since I have intermittent temp readings and speedo quit some time back and odo quit a few months ago)

Further information: When driving, at first the warning lights would all go out above 2500 RPM. Later in the drive it took 4000 RPM and finally they just stayed on.

I'll have a chance to troubleshoot tonight if I can get home on the remaining charge in the battery.

Will print out the charging FAQs but any other advise or experiences are appreciated.

Note: I have two 240's sitting around who could donate alternators or parts if they interchange.


Brian Mee

92 945T
91 240
90 240 DL








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    Alternator Not Charging 900 1992

    posted by  MrNabisco on  Wed Apr 11 13:39 CST 2018
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    last visit: Wed Oct 22 12:36 CST 2014
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    I suggest doing the instrument cluster fix regardless of whether it is your current problem or not. Both 940s I have had the solder joint problem. My guess is it happens to every 940 eventually, so do a little preventive maintenance. I resoldered every single joint on both of my clusters.


    http://www.turbobricks.com/maint.php?content=art0031







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      Alternator Not Charging--Fixed 900 1992

      posted by  BrickDad on  Tue Apr 17 18:58 CST 2018
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      last visit: Fri Oct 24 10:17 CST 2014
      [RELATED]

      OK replacing the voltage regulator restored charging. The alternator bearings seemed to be fine. Short brushes were the most likely culprit. While off I did clean up all the connections.

      The hardest part of the job was getting the pivot bolt off to get the alternator to a bench. The nut had somehow stripped the threads from the bolt and had to be removed with a nut splitter. I replaced the bolt with a length of all-thread.

      The things I thought were aligning pins on the rear plastic cover turned out to be 0.5 mm bolts. Once those were off replacing the voltage regulator was easy.

      Due to time constraints and bad weather I ended up using the 945 for several days as kind of a "plug in hybrid" by charging the battery each night which got me to the commuter train station and back with about 80% battery left each day as long as I didn't use the headlights.

      Brian Mee








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    Alternator Not Charging --Rear cover removal? 900 1992

    posted by  BrickDad on  Tue Apr 10 18:47 CST 2018
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    last visit: Fri Oct 24 10:17 CST 2014
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    It appears to access the voltage regulator and brushes, you must remove the black plastic rear cover. I have taken off all of the nuts and connectors and released the three plastic clips but it seems to still be held by something.

    There are three very tiny bolt looking things but they seem to just be aligning studs.

    Any help appreciated.

    PS The nut on the upper alternator mount bolt seems to be stripped so I'm trying to check the brushes while on the car.

    Brian Mee








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      Alternator Not Charging --Rear cover removal? 900 1992

      posted by  spook on  Wed Apr 11 11:43 CST 2018
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      last visit: Fri Oct 24 08:06 CST 2014
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      Dear Brickdad,

      Hope you're well. If the alternator is the factory-installed item, it has pretty likely reached the end of its service life. Presuming replacement internal parts (e.g., brushes, bearings, etc.) could be found, the commutator might also need to be replaced. The replacement parts are likely to exceed the cost of a re-built unit.

      Thus, I'd look for a re-built unit and use the in-service unit as a "core".

      Hope this helps.

      Yours faithfully,

      Spook








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    Alternator Not Charging 900 1992

    posted by  someone claiming to be CB on  Mon Apr 9 17:14 CST 2018 [RELATED]

    never changed the brushes???
    Start there. 95% if you have never changed out the Reg/Brush Unit.
    And yes the 240 Alt will have the same Re/Brush unit.








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    Alternator Not Charging 900 1992

    posted by  pierso on  Mon Apr 9 15:24 CST 2018
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    last visit: Sun Feb 24 06:56 CST 2013
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    I had a no-charge situation on my old 740 and it turned out to be a dud connection where the charging indicator lamp was on the back of the cluster. I think it needs a circuit through there before it’ll charge. I may be wrong though. If that light comes on it aint that. Have a look at this link in the. FAQ

    https://www.brickboard.com/RWD/volvo/1587308/740/760/780/1991_740_volvo_charging_tried_everything.html

    regards








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    Alternator Not Charging 900 1992

    posted by  bcg on  Mon Apr 9 11:07 CST 2018
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    last visit: Sun Jul 27 08:12 CST 2014
    [RELATED]


    hi brian,
    one other, easy and low cost check is the ground cable, from the alternator to the chassis. one of the least conspicuous items for a ground wire, and not always recognized.

    on my 86 245, mine was all corroded, which i tried to remake with a heavy gauge wire and connector, not really good.

    i wound up just buying a new volvo ground wire, the one with the blue insulation. all fixed.

    regards,
    byron golden
    86 245
    92 245
    94 490







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