2005 SUZUKI JIMNY drive

Downloaded from www.Manualslib.com manuals search engine 6H-6 CHARGING SYSTEM
Diagnosis
Battery
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 appar-
ent reason, the followings are some factors that may point to the
cause of trouble:
Accessories left on overnight or for an extended period with-
out the generator operating.
Slow average driving speeds for short periods.
Electrical load exceeding generator output particularly with
addition of after market equipment.
Defects in charging system such as high resistance, slipping
drive belt, loose generator output terminal, faulty generator
or voltage regulator. Refer to “Generator” in this “Diagnosis”
section.
Battery abuse, including failure to keep battery cable termi-
nals clean and tight or loose battery hold down.
Mechanical problems in electrical system such as shorted or
pinched wires.
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 pre-
cise 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.

Downloaded from www.Manualslib.com manuals search engine CHARGING SYSTEM 6H-7
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 bat-
tery is charged up to the 85% level.
Generator
Trouble in charging system will show up as one or more of follow-
ing conditions:
1) Faulty indicator lamp operation.
2) An undercharged battery as evidenced by slow cranking or
indicator dark.
3) An overcharged battery as evidenced by excessive spewing
of electrolyte from vents.
Noise from generator may be caused by a loose drive pulley,
loose mounting bolts, worn or dirty bearings, defective diode, or
defective stator.
FAULTY INDICATOR LAMP OPERATION
CAUTION:
Do not mistake polarities of IG terminal and L terminal.
Do not make a short circuit between IG and L termi-
nals. Always connect these terminals through a lamp.
Do not connect any load between L and E.
When connecting a charger or a booster battery to
vehicle battery, refer to this section describing battery
charging.
B: Generator output (Battery terminal)
E: Ground
IG: Ignition terminal
L: Lamp terminal
Condition Possible Cause Correction
Charge light does not
light with ignition ON
and engine offFuse blown Check fuse.
Light burned out Replace light.
Wiring connection loose Tighten loose connection.
IC regulator or field coil faulty Check generator.
Charge light does not go
out with engine running
(battery requires fre-
quent recharging)Drive belt loose or worn Adjust or replace drive belt.
IC regulator or generator faulty Check charging system.
Wiring faulty Repair wiring.

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UNDERCHARGED BATTERY
This condition, as evidenced by slow cranking or indicator clear
with red dot can be caused by one or more of the following condi-
tions even though indicator lamp may be operating normal.
Following procedure also applies to cars with voltmeter and
ammeter.
1) Make sure that undercharged condition has not been caused
by accessories left on for extended period of time.
2) Check drive belt for proper tension.
3) If battery defect is suspected, refer to BATTERY section.
4) Inspect wiring for defects. Check all connections for tight-
ness and cleanliness, battery cable connections at battery,
starting motor and ignition ground cable.
5) Connect voltmeter and ammeter as shown in the figure.
6) Measure current and voltage.
No-load Check
1) Run engine from idling up to 2,000 rpm and read meters.
Standard current
10 A maximum
Standard voltage
14.4 – 15.0 V (at 20 °C, 68 °F)
Higher Voltage
If voltage is higher than standard value, check ground of brushes.
If brushes are not grounded, replace IC regulator.
Lower Voltage
If voltage is below or in standard value, increase engine speed up
to 2,000 – 2,500 rpm soon after starting engine, and read maxi-
mum value on ammeter immediately.
If current is less than 49 A, repair or replace generator.NOTE:
Use fully charged battery.
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
NOTE:
Turn off switches of all accessories (wiper, heater etc.).
NOTE:
Consideration should be taken that voltage will differ
somewhat with regulator case temperature as shown in
the graph.

Downloaded from www.Manualslib.com manuals search engine 6H-16 CHARGING SYSTEM
Drive End Bearing
Check that the bearing is not rough or worn.
End Housing Bearing
Check that the bearing is not rough or worn.
When removal is necessary, use bearing puller to remove end
housing bearing (1).
Replace Brush
1) Unsolder and remove the brush and spring.
2) Run the wire of a new brush through the spring and the hole
in the brush holder, and insert the spring and brush into the
brush holder.
3) Solder the brush wire to the brush holder at specified
exposed length.
Exposed brush length
“a” : 10.5 mm (0.413 in.)
4) Check that the brush moves smoothly in the brush holder.
5) Cut off the excess wire.
6) Apply insulation paint to the soldered area.
CAUTION:
Be careful not to distort cooling fan blade while applying
puller.

Downloaded from www.Manualslib.com manuals search engine CHARGING SYSTEM 6H-17
Specifications
Battery
55B24R TYPE

38B20R TYPE
Generator
Tightening Torque Specification
Rated capacity 36 AH/5HR, 12 Volts
Electrolyte 3.1 L (6.55/5.46 US/lmp pt)
Electrolyte S.G. 1.28 when fully charged at 20 °C (68 °F)
Rated capacity 28 AH/5HR, 12 Volts
Electrolyte 2.1 L (4.44/3.70 US/lmp pt)
Electrolyte S.G. 1.28 when fully charged at 20 °C (68 °F)
Type 70 A type
Rated voltage 12 V
Nominal output 70 A
Permissible max. speed 18,000 r/min.
No-load speed 1,300 r/min (rpm)
Setting voltage 14.4 to 15.0 V
Permissible ambient temperature–30 to 90 °C (–22 to 194 °F)
Polarity Negative ground
Rotation Clockwise viewed from pulley side
Fastening partTightening torque
Nm kg-m lb-ft
Body ground bolt 8 0.8 6.0
Generator mounting bolts 23 2.3 16.5
“B” terminal inner nut 4.2 0.42 3.0
“B” terminal outer nut 8 0.8 6.0
Pulley nut 118 11.8 85.5
Rear end frame nuts
4.50.453.5
Rear end cover nuts
Rectifier “B” bolt 3.9 0.39 3.0
Stator stud bolts 8.8 0.88 6.5
Drive end bearing plate screws 2.6 0.26 2.0
Rectifier screws
2.00.201.5
Regulator and brush holder screws
Terminal plate bolt 3.8 0.38 3.0