OVERHAUL
Note. Generator overhaul procedure for Optima & Magentis (Canadian) is not available from the manufacturer.
Note. When removing solder from rectifier leads, DO NOT use soldering iron for more than 5 seconds. Rectifier may be damaged by excessive heat.
Disassembly
- Remove cap screws from front housing. (Scheme 7) Using a 200-watt soldering iron, heat rear of bearing box to allow bearing to be removed from rear housing. Separate front housing from stator.
- Place rotor into a vise and loosen lock nut. Disassemble pulley, rotor and front housing. If necessary, use a socket and hand press or vise to remove front bearing.
- Remove rear bearing with a bearing puller. Remove "B" terminal nut and insulating bushing. Remove screws holding rectifier and brush holder. Separate rear bracket and stator.
- Using soldering iron, remove solder from rectifier and stator leads. Remove regulator. Remove solder from pigtail and remove brush.
Assembly
- When connecting brush, solder pigtail so that wear limit line of brush projects .079-.118" (2-3 mm) out of brush holder. Before assembly, hold brushes in brush holder. Pass a .08" (2 mm) wire 1.6-2.0" (40-50 mm) through hole located in generator housing. Secure brushes in position. Remove wire after assembly is completed.
- Using a socket same size as bearing and a hand press or vise, carefully push in front bearing. When installing rear bearing, ensure groove on bearing rim is on slip ring side. To complete assembly, reverse disassembly procedure. Tighten all bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-99680-S19405256522001072600000) .
