RM35X0E _57 Power Source / Network _078664 7GR-FKS BATTERY / CHARGING _0386628 GENERATOR A

7GR-FKS BATTERY / CHARGING  GENERATOR  REASSEMBLY  


PROCEDURE

Hide 27310 1.INSTALL GENERATOR DRIVE END FRAME BEARING

a.
A363739E02
2.371,0.371 1.851,0.205 1.851,0.205 2.231,0.853 false 1.467,0.107 1.771,0.273 0.304,0.165 10 SST

Using SST and a press, press in a new generator drive end frame bearing.

SST
09950-60011  (09951-00470)
09950-70010  (09951-07100)


b.
A363741C02
2.823,0.813 1.99,0.344 true 2.792,1.24 1.927,1.938 true 1.833,0.229 2.135,0.417 0.302,0.188 10 false *a 1.76,1.844 2.042,2 0.281,0.156 10 false *b
*a Tab
*b Cutout


Fit the tabs on the retainer plate into the cutouts on the drive end frame to install the retainer plate.


c.

Install the 4 screws.

Torque:
2.3 N*m (23 kgf*cm, 20 in.*lbf)


Hide 27330 2.INSTALL GENERATOR ROTOR ASSEMBLY

a.

Place the generator drive end frame on the generator pulley.


b.

Install the generator rotor assembly to the generator drive end frame.


Hide 27444 3.INSTALL GENERATOR BEARING COVER PACKING

NOTICE:

A new generator coil assembly comes with a generator bearing cover packing. Therefore, it is not necessary to install a new generator bearing cover packing when installing a new generator coil assembly.


A314531C15
2.374,0.342 2.649,0.529 0.275,0.187 10 *a 1.919,0.442 2.34,0.442 false 2.376,1.273 2.651,1.459 0.275,0.187 10 *b 1.921,1.372 2.342,1.372 false
*a Protrusion
*b Groove


a.

Install a new generator bearing cover packing to the generator coil assembly.

NOTICE:

Align the protrusion of the generator bearing cover packing with the groove of the generator coil assembly when installing.



Hide 27360 4.INSTALL GENERATOR COIL ASSEMBLY

a.
A375255

Temporarily install the generator coil assembly to the generator drive end frame with the 4 through bolts.

NOTICE:

Because the generator coil assembly must be installed with a press after the through bolts have first been temporarily tightened, do not attempt to install the generator coil assembly by tightening the through bolts only.



b.
A363743C01
1.073,0.333 1.354,0.615 false 2.375,0.177 2.76,0.521 false 2.219,0.083 2.438,0.271 0.219,0.188 10 false *a 0.917,0.219 1.135,0.406 0.219,0.188 10 false *a
*a 21 mm Deep Socket Wrench


Using a 21 mm deep socket wrench and press, slowly press in the generator coil assembly.


c.

Tighten the 4 through bolts.

Torque:
5.6 N*m (57 kgf*cm, 50 in.*lbf)


Hide 27370 5.INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

a.
A079315C09
0.969,0.729 1.24,0.396 1.24,0.396 1.333,0.396 false 1.354,0.302 1.625,0.479 0.271,0.177 10 false *a
*a Pin


While pushing the 2 brushes into the generator brush holder assembly, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the brush holder hole.


b.
A363729C02
1.698,0.99 1.021,1.885 1.021,1.885 0.948,1.885 false 0.75,1.781 0.948,1.979 0.198,0.198 10 false *a
*a Pin


Install the generator brush holder assembly to the generator coil assembly with the 2 screws.

Torque:
1.8 N*m (18 kgf*cm, 16 in.*lbf)


c.

Pull out the pin from the generator brush holder assembly.


Hide 27039 6.INSTALL GENERATOR REAR END COVER

a.
A437145

Install the generator rear end cover to the generator coil assembly with the 3 bolts.

Torque:
4.6 N*m (47 kgf*cm, 41 in.*lbf)


Hide 27387 7.INSTALL TERMINAL INSULATOR

a.
A437146

Install the terminal insulator to the generator coil assembly.

NOTICE:

Make sure the terminal insulator is installed facing the proper direction.



Hide 27411 8.INSTALL GENERATOR PULLEY

a.

Temporarily install the generator pulley by hand.


b.

Mount the generator assembly in the vise between aluminum plates.

NOTICE:

Do not overtighten the vise.



c.
A363721C02
2.24,0.198 2.323,0.198 2.323,0.198 3.073,0.354 false 3.208,0.583 2.927,0.875 2.927,0.875 2.927,1.167 false 2.406,1.979 2.625,2.146 0.219,0.167 10 true *a 1.667,0.115 2.26,0.281 0.594,0.167 10 false SST 1-B 2.667,1.208 3.26,1.375 0.594,0.167 10 false SST 1-A 1.771,1.188 2.083,1.385 0.313,0.198 10 false *b
*a Hold
*b Turn


Install SST 1-A and B to the generator pulley shaft.

SST
09820-63011  (09820-06010, 09820-06021)

Torque:
39 N*m (398 kgf*cm, 29 ft.*lbf)


d.

Install SST 1-B to SST 1-A.

SST
09820-63011  (09820-06010, 09820-06021)


e.

Hold SST 1-A with a torque wrench and turn SST 1-B clockwise with the specified torque.

Torque:
39 N*m (398 kgf*cm, 29 ft.*lbf)

NOTICE:

Make sure that SST is secured to the generator rotor shaft.



f.
A363722C01
1.969,0.729 2.219,0.208 false 2.583,0.719 2.771,0.49 false 2.271,0.125 2.906,0.302 0.635,0.177 10 false SST 1-A 2.813,0.406 3.271,0.583 0.458,0.177 10 false SST 2 2.865,0.708 3.177,0.906 0.313,0.198 10 false *a
*a Insert


Insert SST 2 and attach it to the generator pulley nut.


g.
A363748C01
1.938,0.729 2.094,0.354 2.094,0.354 2.198,0.354 false 1.771,0.719 1.938,0.146 1.938,0.146 1.979,0.146 false 2.229,0.292 2.833,0.5 0.604,0.208 10 false SST 1-A 2.031,0.083 2.635,0.292 0.604,0.208 10 false SST 2 1.521,1.594 1.76,1.802 0.24,0.208 10 false *a 1.979,1.938 2.292,2.135 0.313,0.198 10 false *b
*a Hold
*b Turn


Tighten the generator pulley nut by turning SST 1-A as shown in the illustration.

Torque:
132.5 N*m (1351 kgf*cm, 98 ft.*lbf)


h.

Remove SST 2 from the generator pulley shaft.


i.
A363724C02
3.25,0.604 2.948,1.167 true 3.042,0.365 2.281,0.167 true 2.667,1.167 3.313,1.365 0.646,0.198 10 false SST 1-A 1.729,0.063 2.375,0.26 0.646,0.198 10 false SST 1-B 2.552,1.563 2.833,1.75 0.281,0.188 10 false *a 1.896,1.521 2.208,1.719 0.313,0.198 10 false *b
*a Hold
*b Turn


Turn SST 1-B as shown in the illustration and remove SST 1-A and B.


j.

Turn the generator pulley and check that the generator pulley moves smoothly.


k.

Remove the generator assembly from the vise.