Suzuki Grand Vitara JB419. Manual - part 70

 

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Suzuki Grand Vitara JB419. Manual - part 70

 

 

Charging System:  1J-1

Engine

Charging System

General Description

Battery Description

S5JB0B1A01001

The battery has three major functions in the electrical 
system.
• It is a source of electrical energy for cranking the 

engine.

• It acts as a voltage stabilizer for the electrical system.
• It can, for a limited time, provide energy when the 

electrical load exceeds the output of the generator.

Carrier and Hold-Down
The battery carrier should be in good condition so that it 
will support the battery securely and keep it level. 
Before installing the battery, the battery carrier and hold-
down clamp should be clean and free from corrosion and 
make certain there are no parts in carrier.
To prevent the battery from shaking in its carrier, the 
hold-down bolts should be tight enough but not over-
tightened.

Electrolyte Freezing
The freezing point of electrolyte depends on its specific 
gravity. Since freezing may ruin a battery, it should be 
protected against freezing by keeping it in a fully 
charged condition. If a battery is frozen accidentally, it 
should not be charged until it is warmed.

Sulfation
If the battery is allowed to stand for a long period in 
discharged condition, the lead sulfate becomes 
converted into a hard, crystalline substance, which will 
not easily turn back to the active material again during 
the subsequent recharging. “Sulfation” means the result 
as well as the process of that reaction. 
Such a battery can be revived by very slow charging and 
may be restored to usable condition but its capacity is 
lower than before.

Care of battery

WARNING

!

 

• Never expose battery to open flame or 

electric spark because of battery generate 
gas which is flammable and explosive.

• Do not allow battery fluid to contact eyes, 

skin, fabrics, or painted surfaces as fluid is 
a corrosive acid. Flush any contacted area 
with water immediately and thoroughly.

• Batteries should always be kept out of 

reach of children.

 

1) The battery is a very reliable component, but needs 

periodical attentions.
• Keep the battery carrier clean.
• Prevent rust formation on the terminal posts.
• Keep the electrolyte up to the upper level 

uniformly in all cells.

• When keeping battery on vehicle over a long 

period of time, follow instructions given below.
– Weekly, start the engine and run it until it 

reaches normal operating temperature with 
engine speed of 2000 to 3000 rpm. Make sure 
all electric switches are off before storing the 
vehicle.

– Recharge the battery twice a month to prevent 

it from discharging excessively. This is 
especially important when ambient temperature 
is low.
The battery discharges even when it is not 
used, while vehicles are being stored. Battery 
electrolyte can freeze and battery case can 
crack at cold ambient condition if battery is not 
properly charged.

2) Keep the battery cable connections clean.

The cable connections, particularly at the positive (+) 
terminal post, tend to become corroded. The product 
of corrosion, or rust, on the mating faces of 
conductors resists the flow of current.
Clean the terminals and fittings periodically to 
ensure good metal-to-metal contact, and grease the 
connections after each cleaning to protect them 
against rusting.

3) Be always in the know as to the state of charge of 

the battery. The simplest way to tell the state of 
charge is to carry out a hydrometer test. The 
hydrometer is an instrument for measuring the 
specific gravity (S.G.) of the battery electrolyte. The 
S.G. of the electrolyte is indicative of the state of 
charge. Refer to “Hydrometer Test” in “Battery 
Inspection”.

1J-2 Charging System: 

Generator Description

S5JB0B1A01002

The generator is a small and high performance type with an IC regulator incorporated. The internal components are 
connected electrically as shown in the following figure.
The generator features are as follows:
• Solid state regulator is mounted inside the generator.
• All regulator components are enclosed into a solid mold.
• This unit along with the brush holder assembly is attached to the rear housing.
• The IC regulator uses integrated circuits and controls the voltage produced by the generator, and the voltage setting 

cannot be adjusted.

• The generator rotor bearings contain enough grease to eliminate the need for periodic lubrication. Two brushes 

carry current through the two slip rings to the field coil mounted on the rotor, and under normal conditions will 
provide long period of attention-free service.

• The stator windings are assembled on the inside of a laminated core that forms part of the generator frame.

I5JB0B1A0001-05

1. Generator with regulator assembly

3. Stator coil

5. Field coil (rotor coil)

7. Main switch

9. Load

2. I.C. regulator

4. Diode

6. Charge indicator light

8. Battery

2

2

B

L

IG

C

9

1

3

3

4

5

6

7

8

E

F

I5JB0B1A0002-03

1. Pulley

5. Field coil

9. Drive end frame

L: Lamp terminal

2. Rotor fan

6. Regulator

B: Generator output (Battery terminal)

IG: Ignition terminal

3. Stator coil

7. Brush

E: Ground

C: Dummy

4. Stator core

8. Rear end frame

F: Field coil terminal

Charging System:  1J-3

Diagnostic Information and Procedures

Battery Inspection

S5JB0B1A04001

Common Causes of Failure
A battery is not designed to last indefinitely; however, 
with proper care, it will provide many years of service. If 
the battery performs satisfactorily during test but fails to 
operate properly for no apparent reason, the following 
are some factors that may point to the cause of trouble:
• Accessories leave on overnight or for an extended 

period without the generator operating.

• Slow average driving speeds for short periods.
• Electrical load exceeding generator output particularly 

with addition of aftermarket equipment.

• Defects in charging system such as high resistance, 

slipping drive belt, loose generator output terminal, 
faulty generator or voltage regulator. Refer to 
“Generator Symptom Diagnosis”.

• Battery abuse, including failure to keep battery cable 

terminals clean and tight or loose battery hold down.

• Mechanical problems in electrical system such as 

shorted or pinched wires.

Battery Test
Visual inspection
Check for obvious damage, such as cracked or broken 
case or cover, that could permit loss of electrolyte. 
If obvious damage is noted, replace battery. Determine 
cause of damage and correct as needed.

Hydrometer test
The direct method of checking the battery for state of 
charge is to carry out a high rate discharge test, which 
involves a special precise voltmeter and an expensive 
instrument used in the service shops, but not 
recommendable to the user of the vehicle.
At 20 

°C of battery temperature (electrolyte 

temperature):
• The battery is in FULLY CHARGED STATE if the 

electrolyte S.G. is 1.280.

• The battery is in HALF CHARGED STATE if the S.G. 

is 1.220.

• The battery is in NEARLY DISCHARGED STATE if 

the S.G. is 1.150 and is in danger of freezing.

As the S.G. varies with the temperature, if battery 
temperature is not at 20 

°C (68 °F), you have to correct 

your S.G. reading (taken with your hydrometer) to the 
value at 20 

°C (68 °F) and apply the corrected S.G. value 

to the three-point guide stated value.
For the manner of correction, refer to the graph showing 
the relation between S.G. value and temperature.

How to use the temperature-corrected state-of-
charge graph
Suppose your S.G. reading is 1.28 and the battery 
temperature is –5 

°C (23 °F). Locate the intersection of 

the –5 

°C line and the 1.28 S.G. line.

The intersection is within the “A” zone (shaded area in 
the graph) and that means CHARGED STATE.
To know how much the battery is charged, draw a line 
parallel to the zone demarcation line and extend it to the 
right till it meets with the percentage scale. In the present 
example, the line meets at about 85% point on the 
percentage scale.Therefore, the battery is charged up to 
the 85% level.

[a]: Gravity
[b]: Temperature

I5JB0B1A0003-01

1J-4 Charging System: 

Generator Symptom Diagnosis

S5JB0B1A04002

CAUTION

!

 

• Do not connect any load between “L” and 

“E” terminals.

• When connecting charger or booster 

battery to vehicle battery, refer to “Jump 
Starting in Case of Emergency”.

 

Trouble in charging system will show up as one or more 
of the following conditions:

1) Faulty indicator lamp operation.
2) An undercharged battery as evidenced by slow 

cranking.

3) An overcharged battery as evidenced by excessive 

spewing of electrolyte from vents.

Noise from generator may be caused by loose drive 
pulley, loose mounting bolts, worn or dirty bearings, 
defective diode, or defective stator.

Charging Indicator Lamp Operation

Generator Test (Undercharged Battery Check)

S5JB0B1A04003

This condition, as evidenced by slow cranking or low 
specific gravity can be caused by one or more of the 
following conditions even though indicator lamp may be 
operating normal. The following procedure also applies 
to cars with voltmeter and ammeter.
• Make sure that undercharged condition has not been 

caused by accessories left on for extended period of 
time.

• Check drive belt for proper tension.
• If battery defect is suspected, refer to “Battery 

Description”.

• Inspect wiring for defects. Check all connections for 

tightness and cleanliness, battery cable connections 
at battery, starting motor and ignition ground cable.

No-Load Check

1) Connect voltmeter and ammeter as shown in figure.

NOTE
Use fully charged battery.

 

B: Generator output (Battery terminal)

L: Lamp terminal

E: Ground

IG: Ignition terminal

F: Field coil terminal

C: Dummy

B

L

IG

C

F

E

I5JB0B1A0004-01

Condition

Possible cause

Correction / Reference Item

Charge light does not 
light with ignition ON and 
engine off

Fuse blown

Replace fuse and check for short circuit.

Indicator lamp (LED) faulty

Replace combination meter.

Wiring connection loose

Tighten loose connection.

IC regulator or field coil faulty

Check generator.

Poor contact between brush and slip 
ring

Repair or replace.

Charge light does not go 
out with engine running 
(battery requires frequent 
recharging)

Drive belt loose or worn

Replace drive belt.

IC regulator or generator faulty

Check charging system.

Wiring faulty

Repair wiring.

1. Generator
2. Ammeter (between generator “B” terminal and battery (+) terminal)
3. Voltmeter (between generator “B” terminal and ground)
4. Battery
5. Load
6. Switch

+

A

-

V

+

-

1

B

2

5

6

4

3

I4RH0A1A0005-01

 

 

 

 

 

 

 

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