Manual Transmission

Generator / 7A-FE / Manual Transmission:

GENERATOR DISASSEMBLY / 7A-FE / MANUAL TRANSMISSION







1. REMOVE REAR END COVER
a. Remove the nut and terminal insulator.
b. Remove the clamp from the wire clip on the rectifier end frame.







c. Remove the 3 nuts and end cover.
d. Remove the wire clamp from the end cover.







2. REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR
a. Remove the 5 screws, brush holder and voltage regulator.







b. Remove the brush holder cover from the brush holder.







3. REMOVE RECTIFIER HOLDER
a. Remove the 4 screws and rectifier holder.







b. Remove the 4 rubber insulators.






4. REMOVE PULLEY
a. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
SST 09820-63010

Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)

b. Check that SST (A) is secured to the rotor shaft.







c. Mount SST (C) in a vise.
d. Insert SST (B) into SST (C). and attach the pulley nut to SST (C).







e. To loosen the pulley nut. turn SST (A) in the direction shown in the illustration.

NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn.


f. Remove the generator from SST (C).







g. Turn SST (B). and remove SST (A and B).
h. Remove the pulley nut and pulley.







5. REMOVE RECTIFIER END FRAME
a. Remove the 4 nuts and wire clip.







b. Using SST, remove the rectifier end frame.
SST 09286-46011







c. Using snap ring pliers. remove the generator washer from the rectifier end frame.


ASSEMBLY







1. PLACE RECTIFIER END FRAME ON PULLEY


2. INSTALL ROTOR TO DRIVE END FRAME







3. INSTALL RECTIFIER END FRAME
a. Install the generator washer to the rectifier end frame.

NOTE: Be careful of the generator washer installation direction.






b. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.







c. Install the wire clip and 4 nuts.

Torque: 4.5 N.m (46 kgf.cm, 40 in.lbf)







4. INSTALL PULLEY
a. Install the pulley to the rotor shaft by tightening the pulley nut by hand.
b. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
SST 09820-63010

Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)

c. Check that SST (A) is secured to the pulley shaft.







d. Mount SST (C) in a vise.
e. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).







f. To torque the pulley nut turn SST (A) in the direction shown in the illustration.

Torque: 110.5 N.m (1,128 kgf.cm, 81 ft.lbf)

g. Remove the generator from SST (C).







5. INSTALL RECTIFIER HOLDER
a. install the 4 rubber insulators on the lead wires.

NOTE: Be careful of the rubber insulators installation direction.







b. Install the rectifier holder while pushing it with the 4 screws.

Torque: 2.0 N.m (20 kgf.cm, 17 in.lbf)







6. INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER
a. Install the brush holder cover to the brush holder.

NOTE: Be careful of the holder Installation direction.







b. Place the voltage regulator together with the brush holder horizontally on the rectifier end frame.







c. Install the 5 screws until there is a clearance of approx. 1 mm (0.04 in.) between the brush holder and voltage regulator.

Torque: 2.0 N.m (20 kgf.cm. 17 in.lbf)

d. Fit the brush holder cover.

7. INSTALL REAR END COVER
a. Install the end cover with the 3 nuts.

Torque: 4.4 N.m (45 kgf.cm. 39 in.lbf)

b. Install the terminal insulator with the nut.

Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf)

c. Install the wire clamp.

8. CHECK THAT ROTOR ROTATES SMOOTHLY