Turn out three screws of fastening of a back cover of the generator.
Pic. 13.7. The place of heating the rear cover of the generator with a soldering iron
Using a 200W soldering iron, heat the back cover with the bearing housing for 3-4 minutes or blow hot air for a longer time (pic. 13.7). In conclusion, it is necessary to heat the bearing housing to a temperature of 50–60°C without heating other parts.
While the back cover is still warm, remove the front cover with the rotor by inserting a screwdriver blade between the front cover and the stator core. Be careful not to damage the stator windings. Make sure the rear cover retaining ring is in place. Clean the rotor slip rings with a soft cloth lightly dampened with solvent.
Turn out the screw of a plate of fastening of a voltage regulator and a brush holder. Loosen the outlet fixing nut «IN», remove the washer.
To release the voltage regulator plate, unsolder the connecting wires from the rectifier. Soldering must be done quickly so that the rectifier does not fail due to overheating.
Pic. 13.8. Generator brush control size: A=2–3 mm
Remove the voltage regulator plate and brush holder. Unsolder the old brushes and solder the new ones. After installing new brushes, the wear limit control line on them should be at a distance of 2–3 mm from the brush holder contour (pic. 13.8).
Install the voltage regulator plate and solder the connecting wires. Install the washer and screw on the outlet fixing nut «IN».
Carefully press the brushes in, fix their position with a thin rod or drill, inserting it through the hole in the back cover. The new brushes have special holes into which the retainer enters.
Pic. 13.9. Arrangement of a lock ring of the back bearing
Make sure the rear bearing circlip is in the bearing groove (pic. 13.9). Heat the rear bearing cap in the same way as when removing it, install the rotor and front cap.
Screw in the three screws securing the covers.
Pull out the latch holding the brushes in the retracted position.
Install the generator on the car.
Attention! If the generator has exhausted its resource, it is more expedient to install a new one than to repair the old one.
Attention! Before carrying out repairs, check the availability of spare parts and their cost. For repairs you will need a powerful soldering iron; in addition, certain skills are required.