New to wunderful world of Volvo, so forgive the frustration - battery won't charge. Tested battery - it's ok. Replaced regulator - why are terminal D+ and 61 separate? - dunno, but parts guy says it's the right one for 66 (Bosch VA 14V 30A)and terminals appear connected under regulator body anyway, so ok. Generator number (0 101 302 027 028) corresponds to nothing at Volvo or Bosch. Haynes manual doesn't specify years, just "early" and "late" models... seems my 66 splits the difference? Any way to cross reference this part number? Thanks, Obi Wan, you're my only hope...

66;

Welcome to the forum.

Sorry your first experience is one which involes the electrical system...quite reliable really given the major components are all good old Bosch...only the minor fixtures and components are from that other, British produce of less than reliable electrical components (and will give you gas)...then again, time and mileage take their toll even on the Bosch equipment...

But why do you start by replacing the reg and are asking about gen Nrs...it seems to me you haven't troubleshot the problem adequitely yet...

To check your charging system (presuming a stock system with no Volt or Ampmeter installed), connect a Voltmeter across the battery, start car, watch voltage as you raise revs...it should rise up to 13+V as the genny pulls the system voltage back up to replace energy taken from battery for starting. If this does not occur, the best way to narrow the problem to gen or reg is to perform reciprocity test on genny (running it as a motor, see: http://www.intelab.com/swem/service%20notes.htm#AMP%20Light%20ON), this will help with where you need to look further...

...and if you want more help here, a bit of additional info on your part wouldn't hurt...such as: Was system working when you got there, or are you starting with an unknown...how old is battery, and how did you "test" it?

...and just a friendly suggestion for after you get your charging system back in order: Replace your (double) fuseblock! See: http://www.intelab.com/swem/tech_bulletin_3.htm

Good Hunting...and use the (Electromotive) force, Luke!

The regulator should be OK, about any Bosch generator regulator will work OK.
When I was in Panama I got VW regulators from the Bosch dealer there, made in
Mexico. Worked fine.
How are your generator brushes?
--
George Downs, Bartlesville, Oklahoma, Central US

Haven't checked the brushes yet; I'm sure they need to be replaced, but wanna figure out the generator model so I can get the right ones in hand. Hoping for a call back from Bosch... hey, they just called and said that this generator was for 4 liter+ engines, but was produced in '66! Weird... tech rep thinks pretty much any brush will work. Anyone agree/disagree?

Those generators were used on a wide variety of cars and are quite rugged.
The brushes are the main wear item, along with the bearings and the mounting
holes in the end plates, especially the front one.

There are some variations in brush quality but if a brush will fit,
it'll work. Look closely at the field windings to make sure they
are not coming loose. The tape holding them rots and lets the wires get
to where the armature can wear them through. Fixing them is possible but
hard. There is a fiberglass electrical tape you can refurb with if you
catch them before they unravel. I've done several and it isn't too hard
once you get the pole pieces loose from the shell. Can't use an ordinary
screw driver!
--
George Downs, Bartlesville, Oklahoma, Central US

Update:
Pulled generator. Brushes worn but not horrible. Replaced 'em anyway. Windings and bearing look/feel solid. Cleaned all contacts and put it back.
No change. Generator light is unphased and shines bright.
Pulled fuses and all are intact but varying stages of corrision on contacts.
Are these all the same amp rating? Is 35 correct?
--
1966 1800S in sunny Sandy Eggo