CHARGING SYSTEM Noise Occurs from V-ribbed Belt or Generator Assembly

INSPECTION PROCEDURE

PROCEDURE

1. CONFIRM PROBLEM SYMPTOM

   
   

   1. Confirm the problem symptom.

      Result
      Symptom Proceed to Noise occurs from fan and generator V belt A Noise occurs from generator assembly B

   
   

   B

   CHECK FOR NOISE WHEN ROTOR IS TURNING FREELY Click here

   A

2. CHECK FAN AND GENERATOR V BELT FOR WEAR

   
   

   1. Check the fan and generator V belt for wear or damage.

      OK
      The fan and generator V belt is not worn or damaged.

   
   

   NG

   REPLACE FAN AND GENERATOR V BELT

   OK

3. CHECK GENERATOR WITH CLUTCH PULLEY FOR WEAR

   
   

   1. Check the generator with clutch pulley grooves for wear or damage.

      OK
      The generator with clutch pulley grooves are not worn or damaged.

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

   
   

   B

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

   C

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

   A

4. CHECK FOR NOISE WHILE CLUTCH PULLEY IS OPERATING

   
   

   1. Start the engine and check the generator with clutch pulley for looseness.

      OK
      The generator with clutch pulley is not loose.

   
   

   NG

   TIGHTEN GENERATOR PULLEY WITH CLUTCH TO SPECIFIED TORQUE

   OK

5. INSPECT 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
      The Result Proceed to OK A NG (Generator Assembly (for 80 A Type)) B NG (Generator Assembly (for 100 A Type)) C

   
   

   B

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

   C

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

   A

   INSPECT PULLEY OTHER THAN GENERATOR ASSEMBLY PULLEY

6. CHECK FOR NOISE WHEN ROTOR IS TURNING FREELY

   
   

   1. Perform a road test and check that noise does not occur when decelerating.

      OK
      Noise does not occur.

   2. Stop the engine and check that generator with clutch pulley noise does not occur as the engine stops.

      OK
      Noise does not occur.

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

   
   

   B

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

   C

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

   A

7. CHECK ENGAGEMENT OF GENERATOR WITH CLUTCH PULLEY

   
   

   1. Remove the generator assembly.

      
      

      • for 80 A Type: Click here

      • for 100 A Type: Click here

   2. 

      Hold the generator rotor assembly (fan) in the generator assembly with a screwdriver, and check that the generator with clutch pulley locks when turned from counterclockwise (free turning direction) to clockwise (locking direction).

      OK
      The generator with clutch pulley locks.

      Result
      The 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

   
   

   A

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

   B

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

   C

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

   D

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