Page 301
+
Regulator
OF
Exciter
winding
Exciter diode
Charge control light
To
consumers
+
Battery
S4069
ALTERNATOR
WIRING DIAGRAM, SEV MAKE (EARLIER DESIGN)
Reg.
B+
---I
I
D;
,
ALTERNATOR
l
WIRING DIAGRAM, !i,EV MAKE (LATER DESIGN)
S 7501
SAAB
321-3
Page 302
MAINTENANCE
IMPORTANTS DONT'S
NEVER ground the exciter terminals of the alternator or regulator or the connecting cable.
NEVER reverse the regulator wiring connections.
NEVER disconnect the regulator or the battery
while the alternator is running.
NEVER dismantle the alternator while the battery
is connected.
NEVER start the alternator unless the cable between
"-" on the alternator and "-" on the regulator is
connected.
' NEVER test the alternator-regulator assembly in
the car or on the test bench without the battery connected.
NEVER reverse the battery connections, since this
will result in serious damage to the alternator.
Any necessary repairs should be done by a specialist
electrical workshop; it is essential that disassembly
and testing are properly carried out, as even small
errors may result in extensive damage.
Alternator
No lubrication is necessary. The bearings are lifetime lubricated. Belt tension must be checked at regular intervals. The alternator drive belt should be so taut that it
can be pressed in about 0.4" (1 cm) by a load of 3.3 lb.
(15 N, 1.5 kp).
CAUTION
Before any electric welding is done on a car equipped
with an AC generator (alternator), the battery ground
cable and all wiring to the alternator must be disconnected, as the rectifier diodes may otherwise be damaged.
CHECKING BELT TENSION
1. Adjusting screw
2. Retaining screw
Regulator
The regulator needs neither adjustment nor maintenance.
321-4
SAAB
Page 303
TERMINAL CLAMPS
Regulator
Alternator
D+: Exciter diode output, terminal for regulator D+.
DF: Terminal to exciter winding and for regulator DF.
B+: Battery connection.
The indicator light is.wired to D+ on the voltage regulator. Connection to D- on the regulator is by a wire in
the tripole joint housing.
REGULATOR,
MAKE BOSCH
1. 72 red to D+
2. 49 black to D3. 73 yellow to DF
ALTERNATOR WIRING CONNECTIONS AND COLOR CODE,
MAKE BOSCH
1. 74 gray to B+
2. 72 red to D+
3. 49 black to D4. 73 yellow to DF
REGULATOR,MAKESEV
1. 72 red to D+
2. 49 black to D3. 73 yellow to DF
As from chassis Nos. 99752015230, 99756006328 and
99757002737, only regulators of Bosch manufacture
will be installed.
Only alternators with integrated electronic charging regulators are supplied as from 1979 model.
ALTERNATOR
MAKE SEV
1. 74 gray to B+
2. 72 red to D+
WIRING CONNECTIONS AND COLOR CODE,
3. 49 black to D4. 73 yellow to DF
SAAB
321-5
Page 304
REMOVING AND MOUNTING
1. Disconnect the negative battery lead. Remember that
the engine must be stopped before this is done.
2. Undo the alternator wiring connections, retaining
screw and adjusting screw and take off the drive belt.
3. Lift out the alternator.
4. Remount the alternator, proceeding in the reverse
order.
5. Adjust the tension of the drive belt. The tension
should be such that the belt can be depressed about
0.4" (10 mm) under a load of 15 N (3.5 lb., 1.5 kp).
NOTE
To protect the diodes from overheating during soldering, proceed as follows:
a. Use a well heated soldering iron with a fine tip
to do the job quickly.
b. Hold the wire between the body of the diode
and the soldering point with pliers to conduct
away as much heat as possible.
CHECKING BELT TENSION
1. ·Adjusting screw
2. Retaining screw
Alternator, make Bosch
EARLIER VERSION
ALTERNATOR, MAKE BOSCH (EARLIER VERSION)
1. Drive bearing assembly
2. Stator
3. Slip ring end bracket
4. Rotor
321-6
Page 305
DISASSEMBLING
.1. Hold the belt pulley securely in a suitable tool and unscrew the nut with a 3/4" (19 mm) wrench. Remove
the pulley and fan disc.
2. Mark the position of the tension lug on the drive bearing housing. Undo the bearing housing retaining screws
and withdraw the rotor together with the bearing housing from the stator.
3. Place the drive bearing housing on a suitable backing
surface and carefully press out the rotor. The bearing
can then be removed. Take care that the rotor does
not fall to the floor and suffer damage when it comes
free of the bearing housing.
4. Use a suitable puller to remove the ball bearing from
the slip ring side.
;:
ASSEMBLING
The length of the brushes must be checked before the
alternator is assembled. The minimum is 0.354 in. (9 mm),
but if they are under 0.551 in. (14 mm) they should be
replaced. See section on "Changing brushes".
1. Pack the ball bearings with Bosch Ft 1 v 34 grease.
Press the ball bearing into the housing with the enclosed side facing the drive end.
2. Press the drive bearing housing on to the rotor.
3. Press on the ball bearing on the slip ring side (see illustration). The enclosed side faces the slip rings.
BRUSHES PUSHED UP AND SECURED
5. Insert the rotor and screw the assembly together.
Make sure that the drive bearing housing is correctly
positioned relative to the slip ring bearing housing.
Press the brushes down from the outside with a screwdriver or similar.
PRESSING DOWN THE BRUSHES
6. Fit the fan and belt pulley. Tighten the nut to a torque of 23-29 ft.lb. (34-39 Nm, 3.5-4 kpm).
(If, at the time of overhaul, the fan has done more than
100 000 km, it should be replaced.)
&--
S998
r
· PRESSING THE SLIP RING BALL BEARING INTO POSITION
4. Put the spring washer into the bearing seat. Push up
the brushes and secure them with the brush springs
(this is easier if the brush unit assembly is removed).
SAAB
321-7
Page 306
CHANGING BRUSHES
Min. length of the brushes is 0.354 in. (9 mm). If the alternator is overhauled the brushes shall be replaced if they
are under 0.551 in. (14 mm).
1. Mark the position of the tension lug on the drive bearing housing. Undo the bearing housing retaining screws
and remove the rotor with the bearing housing from the
stator.
2. Undo both nuts holding the rectifier bridge in place.
3. Undo the terminal connecting wire to the brush unit
assembly (AMP-connections).
4. Undo the brush unit assembly retaining screws and remove the assembly.
5. Disconnect the wires with the help of a soldering iron;
the brushes can then be removed. When resoldering the
wire connections, make sure that no solder flows into
the wires.
UNSOLDER ING THE BRUSH UNIT TERMINALS
UNSCREWING
THE BRUSH UNIT ASSEMBLY
6. Push up the brushes and secure them with the brush
springs. Fit the brush unit assembly and make sure
that the spring washer is in its correct place in the
bearing seat.
7. Insert the rotor and screw the a~sembly together. Make
sure that the drive bearing housing is correctly positioned relative to the slip ring bearing housing. Press
the brushes down from the outside with a screwdriver
or similar.
J
REMOVING
321-8
THE BRUSH UNIT ASSEMBLY
SA.Ml
Page 307
,
Alternator, make Bosch
LATER VERSION
~Q®
!\
s
4
S 4061
AL TERNA TOR, MAKE BOSCH (LATER VERSION)
1. Drive bearing assembly
2. Stator
3. Slip ring end bracket
4. Rotor
5. Rectifier unit
3. Separate the stator and slip ring end bracket from the
drive bearing assembly and rotor. Make a mark to indicate the position of the drive bearing assembly relative to the stator and slip ring end bracket.
DISMANTLING
1. Hold the pulley securely by means of a suitable tool
and remove the nut using a 0.87 in (22 mm) wrench.
Remove the pulley and fan.
2. Remove the brush unit assembly from the alternator.
STATOR AND SLIP RING END BRACKET SEPARATED
ROTOR AND DRIVF. BEARING ASSEMBLY
BRUSH UNIT ASSEMBLY REMOVED FROM ALTERNATOR
SAAB
FROM
321-9
Page 308
4. Remove the retaining screws and nut for the rectifier
unit and separate the stator and the rectifier unit from
the slip ring end bracket.
4. Solder the stator cables to the rectifier unit.
5. Reassemble the rectifier unit and the clip ring end
bracket.
6. Place the snap ring for the bearing in the slip ring end
bracket and refit the drive bearing assembly and rotor
s.11011
STATOR AND RECTIFIER UNIT SEPARATED FROM SLIP
RING END BRACKET
5. Unsolder the stator cables from -the rectifier unit.
6. Support the drive bearing assembly on a suitable base
and carefully press out the rotor. The bearing can now
be dismantled. Take care to ensure that the rotor does
not fall and become damaged as it is pressed free from
the bearing assembly.
7. Remove the ball bearing on the slip ring side using a
suitable extractor.
ASSEMBLY
1. Pack the ball bearing with Bosch Ft 1 v 34 grease.
Press the ball bearing into the bearing assembly with
the capped side facing the drive.
2. Press the drive bearing assembly onto the rotor.
3. Press on the ball bearing on the slip ring side (see illustration). Ensure that the capped side faces the slip
PLACING THE SNAP RING IN THE SLIP RING END
BRACKET
to the slip ring end bracket and stator as described
earlier.
7. Check the lengths of the brushes (with the brush unit
assembly removed, the brushes should protrude at
least 0.20 in (5 mm) through the opening) and reassemble the brush unit assembly.
8. Fit the fan and pulley. Make sure that the washers are
installed in t_hecorrect order (see illustration). Tighten
the nut to a torque of 34-39 Nm (23-29 ft-lb., 3.54.0 kpm).
000
S4019
FAN AND PULLEY WITH SPACERS AND WEDGE
(If, at the time of overhaul, the fan has done more than
100 000 km, the fan should be replaced.)
PRESSING THE BALL BEARING INTO PLACE ON THE SLIP
RING SIDE
321-10
SAAB
Page 309
Alternator, SEV make (earlier design)
1
ALTERNATOR,MAKESEV
1. Drive bearing cap
2. Rotor
3. Stator
4. Exciter diodes
5. Slip ring cap
DISASSEMBLY
1.
2.
3.
Remove the contact point retaining screws and
brush holder.
Remove the four socket head screws with square
nuts which hold the alternator together. Mark the
position of the drive bearing housing in relation to
the stator and slip ring cap.
Separate the slip dng cap and stator assembly from
the drive bearing cap, rotor, fan and pulley assembly, using two screwdrivers inserted in the slots on
both sides of the alternator between the stator and
the drive bearing cap. Never insert the screwdrivers
deeper than 0.08" (2 mm) as this may damage the
stator windings.
S-020
SEPARATING THE STATOR AND SLIP RING CAP FROM
THE DRIVE BEARING CAP AND ROTOR
SAU!
321-11
Page 310
4.
5.
6.
Unscrew the nuts and remove the washers from the
positive and negative diode holders.
Separate the slip ring cap from the stator, and at
the same time insert the contact point and brush
holder through the opening for the latter.
Clamp the rotor in a vise using the wooden blocks
intended for the purpose (tool 8580029). Do not
tighten any harder than necessary to avoid deforming ~he armature cores.
9.
10.
Assemble the drive bearing housing, rotor, fan belt
pulley with slip ring housing and stator. Tighten
the mounting screws with a torque of 2.2 ft.lb.
(3 Nm, 0.3 kpm).
Fit the contact piece and the brush unit assembly.
~
7
.
0
0
0
u
0
0
..
p
8
3
4
S 7503
ALTERNATOR
SEV (LATER DESIGN)
1.Belt pulley
2. Fan
3. Drive bearing cap
4. Rotor
Removal
7.
Unscrew the nut and remove the washer, belt pulley, fan, keypiece and spacer. Note which way the
spacer faces.
8. Undo the three screws in the bearing cap.
9. Push the rotor shaft out of the bearing cap with a
suitable puller, e.g. pinion bearing puller (tool
7841158) from the Saab V4 repair kit.
1O. Push the bearing out of the drive bearing cap.
11. · Pull off the bearing at the slip ring end using the
puller mentioned above.
1. Remove the contact points and brush holder retaining
screws.
2. Remove the four socket head screws with square nuts
which hold the alternator together. Unscrew the nuts
and remove the washers from the positive and negative diode holders.
3. Separate the slip ring cap from the alternator using
two screwdrivers inserted in the slots on both sides
of the alternator between the stator and the drive
bearing cap.
Never insert the screwdrivers deeper than 0.08" (2
mm) as this may damage stator windings. At the same
time, guide the contact point and brush holder through
the opening in the slip ring end bracket.
4. Unsolder the cables from the diodes to be replaced.
REASSEMBLY
2.
3.
4.
5.
6.
7.
8.
Press the bearing firmly on to the shaft at the slip
ring end and press on the inner ring.
Press the bearing into the drive bearing cap and
press on the outer ring.
Fit the plate in the bearing cap with the three slotted screws.
Press the drive bearing cap complete with bearing
firmly on to the rotor shaft.
Fit the spacer, keypiece, fan, belt pulley, washer
and nut.
Tighten the nut to 29 ft.lb. (40 Nm, 4 kpm).
Assemble the slip ring cap and the stator, and at
the same time insert the contact point and brush
holder through the opening for the latter. Make
sure that the insulating washers and sleeves on the
positive diode unit are in place. Screw down the
two diode plates.
Check that the O-ring in the slip ring cap bearing
seat is fitted so that the vent hole is not blocked.
321-12
7. Charging regulator and brush holder
8. Recetifier unit
ALTERNATOR, SEV MAKE (LATER DESIGN)
Changing the diodes, SEV alternator (earlier design)
UNSCREWING THE PULLEY NUT; THE ROTOR IS HELD
FAST BY TOOL 8580029
1.
5. Stator
6. Slip ring end cap
Assembly
1. Position the cable socket on the diode holder screws.
2. Place insulating washers, the exciter diode unit and in-
wa
sulating sleeve on the screws of the positive diode holder.
3. Solder the cables in position. Use a hot soldering iron
so that the soldering will be quick to prevent heat
spreading to the diode body. Insert a pair of flat nose
pliers or suchlike between the soldering point and the
diode to conduct the heat away.
The cables should be correctly positioned before they
are soldered. If the diode connector should become
bent, the diode may be damaged.
4. Check that the O-ring in the slip ring cap bearing seat
is fitted so that the vent hole is not blocked.