Replacement

1. REMOVE MAGNETIC SWITCH END COVER

Remove the 3 bolts, end cover, gasket and plunger.

2. INSPECT CONTACT PLATE FOR WEAR

Using vernier calipers, measure the contact plate for depth ol wear.

If the depth of wear is greater than the maximum, replace the contact plate.

3. REMOVE TERMINAL KIT PARTS

(a) Using SST, loosen the terminal nuts. SST 09810-38140

Remove the terminal nut, wave washer, terminal insulator (outside), O-ring, terminal bolt, contact plate and terminal insulator (inside).

Remove the terminal nut, wave washer, terminal insulator (outside), packing, O-ring, terminal bolt, contact plate, terminal insulator (inside).

4. REINSTALL TERMINAL KIT PARTS

Install these new parts:

(1) Terminal insulator (inside)

(2) Contact plate

(3) Terminal bolt

(5) Packing and terminal insulator (outside)

Install the packing to the terminal insulator, and install them.

HINT:

Match the protrusion of the insulator with the indentation of the housing.

(6) Wave washer

(7) Terminal nut NOTICE:

Be careful to install the terminal insulators (inside) and wave washers in the correct direction.

Install these new parts:

(1)

Terminal insulator (inside)

(2)

Contact plate

(3)

Terminal bolt

(4)

O-ring

(5)

Terminal insulator (outside)

(6)

Wave washer

(7)

Terminal nut

NOTICE:

Be careful to install the terminal insulators (inside) and wave washers in the correct direction.

(c) Temporarily tighten the terminal nuts.

B01239

5. TIGHTEN TERMINAL NUT

(a) Put a wooden block on the contact plate and press it down with a hand press. Dimensions of wooden block: 20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.) Press force: 981 N (100 kgf, 221 lbf) NOTICE:

• Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when 981 N (100 kgf, 221 lbf) of force is applied. Gauge pressure:

_100 kgf

Ram diameter (cm) 2

• If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due to coil deformation or the tightening of the nut.

(b) Using SST, tighten the nuts to the specified torque. SST 09810-38140 Torque: 17 Nm (170 kgfcm, 12 ftlbf) NOTICE:

If the nut is over tightened, it may cause cracks on the in side of the insulator.

6. CLEAN CONTACT SURFACES OF CONTACT PLATE AND PLUNGER

Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag.

7. REINSTALL MAGNETIC SWITCH END COVER

Install the plunger, new gasket, end cover with 3 bolts. Torque: 2.5 Nm (26 kgfcm, 23 in.lbf)

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