CHARGING SYSTEM Charging Failure

INSPECTION PROCEDURE

PROCEDURE

1. Click here

   CHECK GENERATOR WITH CLUTCH PULLEY (ON-VEHICLE INSPECTION)

   
   

   1. Start the engine and visually check that the generator rotor assembly (fan) in the generator assembly is operating.

      OK
      The generator rotor assembly (fan) is operating.

      Result
      Test Result Proceed to OK A NG (Generator Assembly (for 80 A Type)) B NG (Generator Assembly (for 100 A Type)) C

   
   
   • AClick here
   • BClick here
   • CClick here
2. Click here

   CHECK GENERATOR WITH CLUTCH PULLEY (UNIT INSPECTION)

   
   

   1. Remove the generator assembly.

      
      

      • for 80 A Type: (Click here)

      • for 100 A Type: (Click here)

   2. Check the installation condition of the generator pulley cap.

      OK
      The generator pulley cap is not loose or missing.

   3. Check for forming of particles due to friction (for dry type pulley) or grease leaks (for wet type pulley).

      OK
      There are no large amount of particles (for dry type pulley) or grease leaks (for wet type pulley).

   4. Check the generator with clutch pulley for misalignment (interference with the generator assembly).

      OK
      The generator with clutch pulley is not misaligned (no interference with the generator assembly).

   5. 

      Turn the generator with clutch pulley clockwise and counterclockwise by hand and check for noise.

      OK
      Noise does not occur when turned in both directions.

   6. Turn the generator with clutch pulley clockwise and counterclockwise by hand and visually check for runout.

      OK
      The generator with clutch pulley does not have runout.

   7. 

      Hold the generator rotor assembly (fan) in the generator assembly with a screwdriver, and check that the generator with clutch pulley locks when turned clockwise and turns freely when turned counterclockwise.

      OK
      The generator with clutch pulley locks when turned clockwise and turns freely when turned counterclockwise.

      Result
      Test Result Proceed to OK (Generator Assembly (for 80 A Type)) A OK (Generator Assembly (for 100 A Type)) B NG (Generator Assembly (for 80 A Type)) C NG (Generator Assembly (for 100 A Type)) D

   
   
   • AClick here
   • BClick here
   • CClick here
   • DClick here
3. Click here

   REPLACE GENERATOR WITH CLUTCH PULLEY (for 80 A Type)Click here

4. Click here

   REPLACE GENERATOR WITH CLUTCH PULLEY (for 80 A Type)Click here

5. Click here

   REPAIR OR REPLACE GENERATOR ASSEMBLY (for 80 A Type)Click here

6. Click here

   REPLACE GENERATOR WITH CLUTCH PULLEY (for 100 A Type)Click here

7. Click here

   REPLACE GENERATOR WITH CLUTCH PULLEY (for 100 A Type)Click here

8. Click here

   REPAIR OR REPLACE GENERATOR ASSEMBLY (for 100A Type)Click here