RM36D0EC _57 Power Source / Network _083089 M20D-FKS BATTERY / CHARGING _0402338 GENERATOR A

M20D-FKS BATTERY / CHARGING  GENERATOR  REASSEMBLY  


PROCEDURE

Hide 27310B 1.INSTALL GENERATOR DRIVE END FRAME BEARING

a.
A401889E01
0.99,1.083 0.427,0.26 0.427,0.26 1.021,0.427 true 2.708,0.833 2.99,0.396 2.99,0.396 2.594,0.521 true 0.135,0.177 0.594,0.375 0.458,0.198 10 false SST 3.021,0.302 3.354,0.5 0.333,0.198 10 false SST

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

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


b.
A431998C03
2.635,1.917 2.865,1.25 true 1.917,0.198 2.094,0.198 2.094,0.198 2.885,0.885 true 1.74,0.104 2.052,0.26 0.313,0.156 10 false *a 2.542,1.938 2.854,2.094 0.313,0.156 10 false *b
*a Tab
*b Cutout


Fit the tabs of the retainer plate into the cutouts of the generator 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 with clutch.


b.
A401891C01
0.51,0.344 0.698,0.344 0.698,0.344 1.125,0.635 false 2.635,1.802 2.635,1.438 false 0.365,0.26 0.677,0.417 0.313,0.156 10 false *1 2.573,1.813 2.885,1.969 0.313,0.156 10 false *2
*1 Generator Rotor Assembly
*2 Generator Drive End Frame


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


Hide 27360 3.INSTALL GENERATOR COIL ASSEMBLY

a.
A401901C01
1.927,0.49 2.417,0.49 true 1.927,1.458 2.417,1.458 true 2.438,0.406 2.75,0.563 0.313,0.156 10 false *a 2.438,1.365 2.75,1.521 0.313,0.156 10 false *b
*a Protrusion
*b Groove


Install a new bearing cover packing.

NOTICE:

Align the protrusions of the bearing cover packing with the grooves of the generator coil assembly when installing.



b.
A401892C01
0.615,0.542 1.208,0.542 false 2.052,0.156 2.208,0.156 2.208,0.156 2.49,0.427 true 0.469,0.448 0.781,0.604 0.313,0.156 10 false *a 1.906,0.052 2.219,0.208 0.313,0.156 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.

Install the 4 bolts.

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


Hide 27370A 4.INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

a.
A153827C22
2.479,0.74 1.979,0.198 1.979,0.198 1.729,0.198 false 0.917,0.521 0.708,0.198 0.708,0.198 0.458,0.198 false 1.521,0.094 1.833,0.313 0.313,0.219 10 false *a 0.271,0.104 0.583,0.323 0.313,0.219 10 false *a
*a Pin (1.0 mm)


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


b.
A334792C01
1.76,1.073 1.76,1.313 false 1.698,1.333 1.896,1.573 0.198,0.24 10 false *a
*a Pin (1.0 mm)
V100136

Pull out


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 hole.


Hide 27387B 5.INSTALL GENERATOR TERMINAL INSULATOR

A399047

a.

Install the generator terminal insulator to the generator coil assembly.

NOTICE:

Be sure to install the generator terminal insulator in the correct orientation.



Hide 27039 6.INSTALL GENERATOR REAR END COVER

A399046

a.

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 27411 7.INSTALL GENERATOR PULLEY

a.

Secure the generator drive end frame in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.



b.
A536809C01
2.917,0.417 2.698,0.177 2.698,0.177 2.198,0.177 true 3.188,0.656 2.896,1.208 2.896,1.208 2.667,1.208 true 1.51,1.917 1.719,2.125 0.208,0.208 10 true *a 1,1.625 1.208,1.833 0.208,0.208 10 true *b 1.646,0.104 2.219,0.292 0.573,0.188 10 false SST1-B 2.104,1.146 2.677,1.333 0.573,0.188 10 false SST1-A
*a Hold
*b Turn


Temporarily install the generator pulley to the rotor shaft with the generator pulley nut.


c.

Fit the rotor shaft end into SST1-A and SST1-B.

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

HINT:
SST1-A, SST1-B 09820-06010
SST2 09820-06021



d.

Hold SST1-A with a torque wrench and turn SST1-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 rotor shaft end.



e.
A536810N01
2.938,0.813 2.771,0.323 2.771,0.323 2.635,0.323 false 2.25,0.25 2.865,0.448 0.615,0.198 10 false SST2

Insert SST2 and attach it to the generator pulley nut.


f.
A536815C01
2.083,0.427 1.698,0.427 true 2.938,1.51 2.813,1.51 2.813,1.51 2.573,0.885 true 1.458,0.354 1.771,0.51 0.313,0.156 10 false *1 1.26,2.938 1.479,3.125 0.219,0.188 10 true *a 2.083,2.76 2.292,2.938 0.208,0.177 10 true *b 3.01,1.438 3.396,1.635 0.385,0.198 10 false SST2
*1 Generator Pulley
*a Hold
*b Turn


Tighten the generator pulley nut by turning SST1-A in the direction shown in the illustration.

Torque:
133 N*m (1356 kgf*cm, 98 ft.*lbf)


g.

Remove SST2 from the generator assembly.


h.
A536812C01
2.917,0.448 2.771,0.208 2.771,0.208 2.188,0.208 true 3.198,0.708 2.917,1.229 2.917,1.229 2.646,1.229 true 1.802,1.729 2.01,1.885 0.208,0.156 10 false *a 0.979,1.708 1.208,1.896 0.229,0.188 10 true *b 1.667,0.146 2.219,0.313 0.552,0.167 10 false SST1-B 2.094,1.167 2.646,1.333 0.552,0.167 10 false SST1-A
*a Hold
*b Turn


Turn SST1-B in the direction shown in the illustration and remove SST1-A and SST1-B.


i.

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