CHARGING SYSTEM Charging Failure

PROCEDURE

1. 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
      Result OK NG

   
   

   NG

   REPLACE GENERATOR WITH CLUTCH PULLEY for 90 A Type: Click here REPLACE GENERATOR WITH CLUTCH PULLEY for 100 A Type: Click here

   OK

2. CHECK GENERATOR WITH CLUTCH PULLEY (UNIT INSPECTION)

   
   

   1. Remove the generator assembly.

      for 90 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
      Result OK NG

   
   

   OK

   REPAIR OR REPLACE GENERATOR ASSEMBLY for 90 A Type: Click here REPAIR OR REPLACE GENERATOR ASSEMBLY for 100 A Type: Click here

   NG

   REPLACE GENERATOR WITH CLUTCH PULLEY for 90 A Type: Click here REPLACE GENERATOR WITH CLUTCH PULLEY for 100 A Type: Click here