ADJUSTABLE VOLTAGE REGULATORS W O R L D W I D E   S H I P P I N G

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	Web www.davebarton.com

Adjustable Voltage Regulators
for your Volvo (Bosch type alternator)
and many other Bosch Alternators
(VW, Audi, Alfa Romeo, BMW, Porsche and more)
   CLICK HERE FOR INSTALLATION TIPS

Customer Comments: "I finally have appropriate alternator output voltage.  My car has never had enough voltage from its charging system.  I installed your regulator, and was thrilled by the results.  My Autronic SM2 engine management system is much happier.  It idles noticeably better now, and I expect longer battery life as well.   Thank you for an excellent product.  Thank you for your fast service."   R.L., 1984 BMW 633 CSi/Dinan turbo/SM2 "Installed both regulators.  First thing I noticed was that both cockpit voltmeters were off by about a volt or more.  Knowing the voltage at the battery terminals is a great relief.  Both regulators tuned to 14.5 volts and seem to working GREAT.  Thanks for making these fabulous products available."  '79 BMW R100RS motorcycle and '84 BMW 663CSi,  J.M., Jacksonville, FL. "I wish I would have found this adjustable voltage regulator when I first got my 142 3 years ago...It is awsome!!!  I guess I didn't know how bad I needed it until I fried another alternator!!!   Your site is on my favorites now, thanks for the good communication and quick shipping!!!  Volvo 142, C.B., Denver, CO.

All parts are new.  None are refurbished.

External Adjustable Regulator Kit. 

(Please read WARNINGS regarding installation. Click Here)

 

ORDER HERE.  External Adjustable Regulator Kit.  IN STOCK Available in 28 mm slip ring type only. A 20% discount applies on orders of TWO or more kits (i.e.: two for $38.40 each plus shipping) Your discount will be computed in the cart upon check-out. Price: $48.00 plus shipping Order Quantity (USA shipping only):   After clicking "Add to Cart" above, please select your preferred Shipping below. Shipping will NOT add automatically. Shipping for External Regulator Kit or Parts. Please Select Shipping and click "Add to Cart" USA Shipping: USA Shipping Options Priority Mail $7.00 Shipping to CANADA: Canada Shipping Options Priority Mail Insured Canada $19.00 First Class Mail insured Canada $5.00 Other International Shipping: International Shipping Options International Priority Mail Insured $30.00 International First Class Mail insured $10.00 Additional purchase or shipping cost may be added here: please choose amount $0.00 $1.00 $2.00 $3.00 $4.00 $5.00 $6.00 $7.00 $8.00 $9.00 $10.00 $11.00 $12.00 $13.00 $14.00 $15.00 $16.00 $17.00 $18.00 $19.00 $20.00 $21.00 $22.00 $23.00 $24.00 $25.00 $26.00 $27.00 $28.00 $29.00 $30.00 $31.00 $32.00 $33.00 $34.00 $35.00 $36.00 $37.00 $38.00 $39.00 $40.00 $41.00 $42.00 $43.00 $44.00 $45.00 $46.00 $47.00 $48.00 $49.00 $50.00 $100.00 To View Cart or Check Out please click below: RELATED ITEM: Do you need a Replacement Brush Assembly for the above kit? Price: $16.00 plus shipping Order Quantity: 20% discount applies on orders of TWO or more or these too. Shipping cost is the same for one or multiple items. U.S.A. shipping:   $7.00 for Priority Mail insured. Canada shipping: International Priority Mail insured: $19.00 (estimated delivery in 5 to 10 days)                                    First Class Mail Canada (insured): $5.00 (delivery is slower) International Shipping (all other countries):  International Priority Mail insured: $30.00 (5 to 10 days)                                                                                    First Class Mail Int'l (insured): $10.00 (delivery is slower)

External Voltage Regulator (regulator only):
 
This adjustable external regulator is the same one included in the above full kit, but is available separately also.    

This regulator corresponds to the following Volvo Part Numbers:

  

ORDER HERE:  External Adjustable Regulator Only.  In Stock. 20% discount applies on orders of TWO or more (i.e.: two for $25.60 each plus shipping) Your discount will be computed in the cart upon check-out. Price: $32.00 plus shipping Order Quantity: After clicking "Add to Cart" above, please select your preferred Shipping below. Shipping will not add automatically. Shipping for External Regulator. Please Select Shipping for this Item and click "Add to Cart"                             USA Shipping: USA Shipping Options Priority Mail USA $6.00 Shipping to CANADA: Canada Shipping Options Priority Mail Insured Canada $19.00 First Class Mail insured Canada $5.00 Other International Shipping: International Shipping Options International Priority Mail Insured $30.00 International First Class Mail insured $6.00 Additional purchase or shipping cost may be added here: please choose amount $0.00 $1.00 $2.00 $3.00 $4.00 $5.00 $6.00 $7.00 $8.00 $9.00 $10.00 $11.00 $12.00 $13.00 $14.00 $15.00 $16.00 $17.00 $18.00 $19.00 $20.00 $21.00 $22.00 $23.00 $24.00 $25.00 $26.00 $27.00 $28.00 $29.00 $30.00 $31.00 $32.00 $33.00 $34.00 $35.00 $36.00 $37.00 $38.00 $39.00 $40.00 $41.00 $42.00 $43.00 $44.00 $45.00 $46.00 $47.00 $48.00 $49.00 $50.00 $100.00 To View Cart or Check Out please click below: Shipping cost is the same for one or multiple items. U.S.A. shipping:   $6.00 for Priority Mail insured. U.S.A. shipping:   $3.00 for First Class Mail insured. Canada shipping: International Priority Mail insured: $19.00 (estimated delivery in 5 to 10 days)                                    First Class Mail Canada insured: $5.00 (delivery is slower) International Shipping (all other countries):  International Priority Mail Insured: $30.00 (5 to 10 days)                                                                                    First Class Mail Int'l insured: $6.00 (delivery is slower)

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Internal Adjustable Voltage Regulator
 
This complete regulator/brush assembly can be installed in your alternator in place of your original Bosch or Bosch-type non-adjustable regulator.  It's an all-in-one part and can be adjusted to approximately 15 volts (I recommend a limit of 14.5 measured at the battery).  This style seems to be preferred in the Volvo 740/760 or 940/960 series cars where the alternator is mounted high in the engine bay and the back of the alternator is more easily accessible for adjustment.  This regulator will work in a 240 also, but access to the adjustment screw might be obstructed as mentioned above.   

Adjustment is done with a small screwdriver in the hole you see in the back of the regulator; Clockwise to increase voltage, counter-clockwise to decrease voltage.

(Please read WARNINGS regarding installation.  Click here)

  

ORDER HERE: Internal Adjustable Regulator  In Stock Available in 28 mm slip ring (most common) or 32 mm slip ring type. A 20% discount applies on orders of TWO or more (i.e.: two for $25.60 each plus shipping) Your discount will be computed in the cart upon check-out. Price: $32.00 plus shipping Order Quantity: 28 mm Type 32 mm Type After clicking "Add to Cart" above, please select your preferred Shipping below. Shipping will NOT add automatically. Shipping for Internal Regulator. Please Select Shipping for this Item and click "Add to Cart"                             USA Shipping: USA Shipping Options Priority Mail USA $6.00 Shipping to CANADA: Canada Shipping Options Priority Mail Insured Canada $19.00 First Class Mail insured Canada $5.00 Other International Shipping: International Shipping Options International Priority Mail Insured $30.00 International First Class Mail insured $6.00 Additional purchase or shipping cost may be added here: please choose amount $0.00 $1.00 $2.00 $3.00 $4.00 $5.00 $6.00 $7.00 $8.00 $9.00 $10.00 $11.00 $12.00 $13.00 $14.00 $15.00 $16.00 $17.00 $18.00 $19.00 $20.00 $21.00 $22.00 $23.00 $24.00 $25.00 $26.00 $27.00 $28.00 $29.00 $30.00 $31.00 $32.00 $33.00 $34.00 $35.00 $36.00 $37.00 $38.00 $39.00 $40.00 $41.00 $42.00 $43.00 $44.00 $45.00 $46.00 $47.00 $48.00 $49.00 $50.00 $100.00 To View Cart or Check Out please click below: Shipping cost is the same for one or multiple items. U.S.A. shipping:   $6.00 for Priority Mail insured. Canada shipping: International Priority Mail insured: $19.00 (estimated delivery in 5 to 10 days)                                    First Class Mail Canada insured: $5.00 (delivery is slower) International Shipping (all other countries):  International Priority Mail Insured: $30.00 (5 to 10 days)                                                                                    First Class Mail Int'l insured: $6.00 (delivery is slower)

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Internal Voltage Regulator, non-adjustable, 14.5 volt set point.
This internal regulator can be installed in your alternator in place of your original Bosch or Bosch-type regulator. 
Factory set for 14.5 volts (standard non-adjustable regulators are set at 14.1 volts). 

ORDER HERE: Internal Regulator, non-adjustable 14.5 volt set point If you don't need an adjustable regulator, this will be the one you need. 28 mm type only. These are factory set for 14.5 volts (higher than the standard 14.1 volt type). A 20% discount applies on orders of TWO or more (i.e.: two for $19.20 each plus shipping) Your discount will be computed in the cart upon check-out. IN STOCK Price: $24.00 plus shipping Order Quantity: Regulator, 28 mm non-adjustable After clicking "Add to Cart" above, please select your preferred Shipping below. Shipping will not add automatically. Shipping for Internal Regulator. Please Select Shipping for this Item and click "Add to Cart"                             USA Shipping: USA Shipping Options Priority Mail USA $6.00 Shipping to CANADA: Canada Shipping Options Priority Mail Insured Canada $19.00 First Class Mail insured Canada $5.00 Other INTERNATIONAL Shipping: International Shipping Options International Priority Mail Insured $30.00 International First Class Mail insured $5.00 Additional purchase or shipping cost may be added here: please choose amount $0.00 $1.00 $2.00 $3.00 $4.00 $5.00 $6.00 $7.00 $8.00 $9.00 $10.00 $11.00 $12.00 $13.00 $14.00 $15.00 $16.00 $17.00 $18.00 $19.00 $20.00 $21.00 $22.00 $23.00 $24.00 $25.00 $26.00 $27.00 $28.00 $29.00 $30.00 $31.00 $32.00 $33.00 $34.00 $35.00 $36.00 $37.00 $38.00 $39.00 $40.00 $41.00 $42.00 $43.00 $44.00 $45.00 $46.00 $47.00 $48.00 $49.00 $50.00 $100.00 To View Cart or Check Out please click below: Shipping cost is the same for one or multiple items. U.S.A. shipping:   $6.00 for Priority Mail insured. Canada shipping: International Priority Mail insured: $19.00 (estimated delivery in 5 to 10 days)                                    First Class Mail Canada insured: $5.00 (delivery is slower) International Shipping (all other countries):  International Priority Mail Insured: $30.00 (5 to 10 days)                                                                                    First Class Mail Int'l insured: $6.00 (delivery is slower)

Different cars can have different levels of improvement according to the state of your charging system and the amperage rating of your alternator.  An 80 or 100 amp alternator will alway perform better under load than a smaller 55 amp type.  My car was a good test for this regulator and the improvement was dramatic to say the least.  Your own results may vary.

Customer Comment:
"Just wanted to thank you for the regulator and let you know it's working very well.  I'm quite impressed with how well made it is, and how easily the voltage is adjusted.  The dashpot is very smooth and linear in how it varies the voltage."

Frequently Asked Question:
Will an adjustable regulator make my alternator always hold voltage at 14.2 volts like I want it to?  My alternator output seems to drop at times, expecially with several things on at one time, like high-beams and air conditioning.

Answer: An adjustable regulator will raise your voltage initial set-point.  A stock Bosch regulator usually has a factory set-point at 14.1 to 14.2v. Rarely will you actually see that much voltage with a stock regulator. And it will usually drop considerably under load and when hot.  An alternator that has a smaller amp rating (such as 55 amps) will not hold a voltage set-point as well as one with 70, 80, 100 amps or higher when more load is added.  So the answer is that it will likely still drop with load and heat.  The benefit of setting your own higher initial set-point is that it will allow your charging system to handle loads better or even higher to some degree.  For example, when my '84 242 Turbo had the original 55 amp alternator, the stock regulator usually had an output of about 13.8v with no accessories on. It would dip to below 12v with the A/C or other high-load things running.  With the adjustable regulator, I was able to set it for 14.5v, but it still dropped some with my headlights on or when my A/C came on, but the drop became acceptable.  A larger alternator from a later car with 80 or 100 amp capacity would improve the voltage drop under load.

For BEST access to the rear of the alternator in a Volvo 240, you should remove it from the car.  If you have a car with the alternator in a better position, where you have lots of room to work behind it, then it may be installed while the alternator remains in the car.  If you are not confident in your abilities with this type of installation, I recommend you have someone with experience help or have a professional install it for you.  It is easy to permanently damage the regulator when installing if you don't know what you're doing (see damage photo near bottom of page).  The brushes are fragile and will BREAK if much force is placed on them. 

In this photo, you can see the old internal voltage regulator attached to the back of the alternator.  It's the black box thing (also below left photo).  It's attached by two screws (sometimes slotted, sometimes Phillips)... a very simple removal... no wires to disconnect.  If you are working on a 240 Turbo, you will definitely need to remove the alternator, since it will be impossible to get in behind it while still mounted in place.

Here's a photo of the old internal regulator I removed from my '80 242.  It looks like an aftermarket  type.   This 1980 DL (as did many early Volvos) was originally equipped with a factory Bosch external voltage regulator very similar to the one being installed now, except that it was not adjustable.  Somewhere along its life, a previous owner must have "modernized" the car and installed this internal one.
 

Here's the new brush assembly for the external regulator kit.  Don't forget to remove the pin on this brush assembly before installation so the brushes will extend as needed.  The pin is only there for shipping or storage.   NOTE: During these procedures it is best not to handle the brushes with your greasy hands as you can contaminate them and reduce their efficiency and life.
 
 
 
 
  

Now the new brush assembly is installed in the alternator.  I have also securely mounted the external regulator (the silver metal box near the radiator fan). You can see the harness connecting the two components. It really couldn't be much simpler. The regulator can be mounted anywhere under your hood within the 30 inch reach of the harness (or elsewhere if you request a longer harness).

Total installation time for me was about 45 minutes, but a first-timer might be longer.

After reconnecting the battery, I started the car and checked the voltage (measuring it at the battery).  The factory preset voltage for this regulator seemed to be around 14 volts.  I like it a little higher, so I used a small screwdriver to turn the voltage up to 14.5 volts, before turning on any accessories.  The little screw needs to be turned clockwise just a little bit.  The screw is very sensitive. Also, do not try to force the screw past its limit as you will damage the regulator. 

IMPORTANT:  I do not recommend adjusting this regulator without knowing the voltage.  You should use a real voltage meter hooked up at the battery to see what you are setting it at.  And please don't rely on your in-dash volt gauge, unless you have verified its accuracy.  They are not always accurate.  Do yourself a favor and buy an inexpensive digital meter to accurately measure your voltage at the battery.

NOTE:  When installing a new part like this, it's common to find it making lower voltage on the first start-up.  The brushes are there to make electrical contact with the slip rings inside your alternator.  Sometimes is takes running the car for a couple minutes before those contacts wear in and work perfectly. 

A MOST EXCELLENT CUSTOMER INSTALLATION REPORT:
From Zack P.
"My recent (external) adjustable voltage regulator installation went really well. Thanks for making such a nice product. I thought you might be interested to see a clean and simple installation of the remote adjuster in my Volvo 240 (photos at right).  It turns out that the 240 cage/bracket that secures the windshield washer fluid tank has a perfectly good spot for mounting the adjuster bracket; in fact, one of the necessary mounting holes was already there. I removed the washer tank to gain access and space so I could drill the other bolt hole, and then I used two flush/recessed blind nuts to secure the mounting bolts from the back-side and it worked out perfectly. It kind of even looks stock!  Just thought I'd share, since it worked out so well...  Thanks again."


FAILURE TO CHARGE ISSUES

Here's a photo of the Internal Adjustable Voltage Regulator in a typical Bosch IR/EF (Internal Regulator/External Fan) alternator from a 740 GLE.  Installation is much easier if the alternator is removed.  The adjusting screw can be seen in the back of this internal regulator.
 
 
 
 
 
 
 
 
 
 
 

WARNING: Doing Your Own Installation? Electrical Parts such as these special regulators are delicate and do not hold up well to abuse.  If you are not experienced with this sort of installation, then I STRONGLY recommend you have a professional or someone with experience install it for you.  Otherwise, if you force the crud out of it and destroy it, please don't write me and tell me it simply "fell apart" on its own like this customer did. Please put your claw hammers away before installing one of these.

ALTERNATOR TESTING
If you are using an external regulator with a separate brush assembly, the below Full Field Test method will be pretty easy to do.  It will determine how well your alternator is charging.  In case of a problem, this procedure can help you decide if the alternator is at fault or if the regulator is at fault. This test is standard procedure in older shop manuals.

Basically, you'll be bypassing the regulator, so a full 12V is applied to the alternator rotor winding. The battery voltage should go to about 16V, so you should only run the engine just long enough to measure the voltage.

On the wire harness I supply with the External Kit, the wire colors are: D- (BLACK), D+ (RED), DF (GREEN), which will be for Ground, Posative, and Field.  The bypass is applied by unplugging the regulator harness at the regulator end and jumpering the D+ (RED) and DF (GREEN) socket pins.   The remaining D- (BLACK) pin is already grounded to the alternator case as it should be.

If you get around 16V or more, the alternator is good and the problem is likely the regulator or other wiring in the car.

The same test can be done with an internal type regulator setup by replacing the brush/regulator assembly with one that has been modified (regulator portion removed) with an internal jumper between the D+ and DF pins. This could be made from an old bad internal regulator unit. Just make sure the brushes are still in good shape. 

A good Brickboard discussion on Alternator Wear and Slip Rings:
http://www.brickboard.com/RWD/index.htm?id=725699

ALTERNATIVE MODS TO EXISTING REGULATORS
http://articles.mbz.org/electric/regulator/

OTHER LINKS
But what if I think my alternator is bad?
You might check out the following for tips on diagnosing a bad alternator....
http://www.misterfixit.com/alterntr.htm
http://www.humanspeakers.com/audi/alternator.htm
 

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