Get Charging System Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

CHARGING SYSTEM 6H-1

SECTION 6H

CHARGING SYSTEM

CONTENTS

GENERAL DESCRIPTION 6H- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery 6H- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator 6H- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGNOSIS 6H- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery 6H- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator 6H- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 6H-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery 6H-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Jump starting in case of emergency with auxiliary (booster) battery 6H-10. . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 6H-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handling 6H-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 6H-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator 6H-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 6H-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 6H-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator (Water Pump) Belt 6H-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Belt tension inspection 6H-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 6H-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 6H-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNIT REPAIR OVERHAUL 6H-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator 6H-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly 6H-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection 6H-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replace Brush 6H-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly 6H-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS 6H-22

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL DESCRIPTION

BATTERY

The battery has three major functions in the electrical system.

D It is a source of electrical energy for cranking the engine.

D It acts as a voltage stabilizer for the electrical system.

D It can, for a limited time, provide energy when the electrical load

exceeds the output of the generator.

The battery mounted in each vehicle is the following type.

38B20R TYPE

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 fro-

zen 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, crystal-

line substance, which will not easily turn back to the active material

again during the subsequent recharging. “Sulfation” means the re-

sult 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.

6H-2 CHARGING SYSTEM

Rated capacity 28 AH/5HR, 12 Volts

Electrolyte S.G.

1.24 when fully charged at 20 C

(68 F)

CARE OF BATTERY

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

attentions.

Keep the battery carrier clean; prevent rust formation on the ter-

minal posts; keep the electrolyte up to the upper level uniformly

in all cells.

When keeping battery on vehicle over a long period of time, fol-

low instructions given below.

D Weekly, start the engine and run it until it reaches normal op-

erating temperature with engine speed of 2000 to 3000 rpm.

Make sure all electric switches are off before storing the ve-

hicle.

D Recharge the battery twice a month to prevent it from dis-

charging excessively. This is especially important when am-

bient temperature is low.

The battery discharges even when it is not used, while ve-

hicles 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 cur-

rent.

Clean the terminals and fittings periodically to ensure good met-

al-to-metal contact, and grease the connections after each

cleaning to protect them against rusting.

WARNING:

D Never expose battery to open flame or electric spark

because of battery generate gas which is flammable

and explosive.

D 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 thor-

oughly.

D Batteries should always be kept out of reach of chil-

dren.

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 measur-

ing the specific gravity (S.G.) of the battery electrolyte. The S.G.

of the electrolyte is indicative of the state of charge. Refer to

“BATTERY” of DIAGNOSIS in this section.

CHARGING SYSTEM 6H-3

6H-4 CHARGING SYSTEM

GENERATOR

The generator is a small and high performance type with an IC regulator incorporated.

The internal components are connected electrically as shown below figure.

The generator features are as follows:

D Solid state regulator is mounted inside the generator.

D All regulator components are enclosed into a solid mold.

D This unit along with the brush holder assembly is attached to the rear housing.

D The IC regulator uses integrated circuits and controls the voltage produced by the generator, and the voltage

setting cannot be adjusted.

D 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.

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

1. Generator with regulator ass’y

2. I.C. regulator

3. Stator coil

4. Diode

5. Field coil (rotor coil)

6. Charge indicator light

7. Main switch

8. Battery

1. Pulley

2. Pulley nut

3. Rotor fan

4. Stator coil

5. Stator core

6. Field coil

7. Regulator

8. Brush

9. Rear end frame

10. Drive end frame

B : Generator output (Battery terminal)

D : Dummy terminal

E : Ground

F : Field coil terminal

IG : Ignition terminal

L : Lamp terminal

CHARGING SYSTEM 6H-5

DIAGNOSIS

BATTERY

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 it the electrolyte

S.G. is 1.24.

— 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 rela-

tion between S.G. value and temperature at the left.

HOW TO USE THE TEMPERATURE-CORRECTED

STAGE-OF-CHARGE GRAPH

Suppose your S.G. reading is 1.24 and the battery temperature is

–5 _C (23_F). Locate the intersection of the –5 _C line and the 1.24

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.

6H-6 CHARGING SYSTEM

GENERATOR

CAUTION:

D Do not mistake polarities of IG terminal and L terminal.

D Do not create a short circuit between IG and L termi-

nals. Always connect these terminals through a lamp.

D Do not connect any load between L and E.

D When connecting a charger or a booster battery to ve-

hicle battery, refer to this section describing battery

charging.

B : Generator output (Battery terminal)

D : Dummy terminal

E : Ground

F : Field coil terminal

IG : Ignition terminal

L : Lamp terminal

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

conditions:

1) Faulty indicator lamp operation.

2) Undercharged battery as evidenced by slow cranking or indica-

tor dark.

3) 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 defec-

tive stator.

CHARGING SYSTEM 6H-7

FAULTY INDICATOR LAMP OPERATION

PROBLEM

POSSIBLE CAUSE CORRECTION

Charge light does not

light with ignition ON

and engine off

D Fuse blown

D Light burned out

D Wiring connection loose

D IC regulator or field coil faulty

D Poor contact between brush and slip ring

Check fuse.

Replace light.

Tighten loose connection.

Check generator.

Repair or replace.

Charge light does not

go out with engine running

(battery requires

frequent recharging)

D Drive belt loose or worn

D IC regulator or alternator faulty

D Wiring faulty

Adjust or replace drive belt.

Check charging system.

Repair wiring.

UNDERCHARGED BATTERY

This condition, as evidenced by slow cranking can be caused by

one or more of the following conditions even though indicator lamp

may be operating normal.

Following procedure also applies to cars with voltmeter and amme-

ter.

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 tightness

and cleanliness, battery cable connections at battery, starter

and ignition ground cable.

5) Connect voltmeter and ammeter as shown in figure.

Voltmeter

Set between generator B terminal and ground.

Ammeter

Set between generator B terminal and battery (+) terminal.

NOTE:

Use fully charged battery.

6) Measure current and voltage.

1. Generator

2. Ammeter

3. Voltmeter

4. Battery

5. Load

6. Switch

Ammeter between generator (B) terminal

and battery (+) terminal

Voltmeter between

generator (B) terminal

and ground

No-load Check

1) Run engine from idling up to 2,000 rpm and read meters.

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

graph.

6H-8 CHARGING SYSTEM

Standard current 10 A

Standard voltage

14.2 – 14.8 v

Standard

voltage

at 25 _C (77 _F)

Higher Voltage

If voltage is higher than standard value, check ground of brush.

If brush ground is correct, replace IC regulator.

Lower Voltage

If voltage is lower than standard value, proceed to following check.

2) Ground F terminal and start engine, then measure voltage at B

terminal as shown in figure.

D Voltage is higher than standard value

It is considered that generator itself is good but IC regulator

has been damaged, replace IC regulator.

D Voltage is lower than standard value

Generator itself has problem, check the generator.

Load Check

1) Run engine at 2,000 rpm and turn on head light and heater mo-

tor.

2) Measure current and if it is less than 20 A repair or replace gen-

erator.

OVERCHARGED BATTERY

1) To determine battery condition, refer to Battery section in this

DIAGNOSIS.

2) If obvious overcharge condition exists as evidenced by exces-

sive spewing of electrolyte, proceed to disassembly section of

generator service and check field windings for grounds and

shorts. If problem exists, replace rotor.

3) With engine running at 2,000 rpm, measure voltage.

4) If measured voltage is out of standard value, check brush

ground or IC regulator.

CHARGING SYSTEM 6H-9

ON-VEHICLE SERVICE

BATTERY

JUMP STARTING IN CASE OF EMERGENCY WITH

AUXILIARY (BOOSTER) BATTERY

Both booster and discharged battery should be treated carefully

when using jumper cables. Follow procedure outlined below, being

careful not to cause sparks.

1) Set parking brake and place manual transmission in NEUTRAL.

Turn off ignition, turn off lights and all other electrical loads.

2) Check electrolyte level. If it is below low level line, add distilled

water.

3) Attach end of one jumper cable to positive terminal of booster

battery and the other end of the same cable to positive terminal

of discharged battery. (Use 12-volt battery only to jump start en-

gine).

4) Attach one end of the remaining negative cable to negative ter-

minal of booster battery, and the other end to a solid engine

ground (such as exhaust manifold) at least 45 cm (18 in.) away

from battery of vehicle being started.

5) Start engine of vehicle with booster battery and turn off electrical

accessories. Then start engine of the vehicle with discharged

battery.

6) Disconnect jumper cables in the exact reverse order.

WARNING:

D Departure from these conditions or procedure de-

scribed below could result in:

1) Serious personal injury (particularly to eyes) or

property damage from such causes as battery ex-

plosion, battery acid, or electrical burns.

2) Damage to electronic components of either vehicle.

D Remove rings, watches, and other jewelry. Wear ap-

proved eye protection.

D Be careful so that metal tools or jumper cables do not

contact positive battery terminal (or metal in contact

with it) and any other metal on vehicle, because a short

circuit could occur.

WARNING:

Do not connect negative cable directly to negative ter-

minal of dead battery.

6H-10 CHARGING SYSTEM

With Charging Equipment

CAUTION:

When jump starting engine with charging equipment, be

sure equipment used is 12-volt and negative ground. Do

not use 24-volt charging equipment. Using such equip-

ment can cause serious damage to electrical system or

electronic parts.

REMOVAL

1) Open engine hood.

2) Disconnect negative cable (1).

3) Disconnect positive cable (2).

4) Remove retainer (3).

5) Remove battery (4).

HANDLING

When handling battery, following safety precautions should be fol-

lowed:

D Hydrogen gas is produced by battery. A flame or spark near bat-

tery may cause the gas to ignite.

D Battery fluid is highly acidic. Avoid spilling on clothing or other

fabric. Any spilled electrolyte should be flushed with large quan-

tity of water and cleaned immediately.

INSTALLATION

1) Reverse removal procedure.

2) Torque battery cables.

NOTE:

D Check to be sure that ground cable has enough clear-

ance to hood panel by terminal.

D Body and battery cable should not interfere with each

other.

D After tightening positive terminal, be sure to put cap

onto it securely.

CHARGING SYSTEM 6H-11

GENERATOR

1. Adjusting bolt

2. Generator

3. Pivot bolt

4. “B” terminal wire

5. Coupler

6. Nut

: Tightening Torque

REMOVAL

1) Disconnect negative cable (1) at battery (2).

2) Remove front bumper.

3) Disconnect “B” terminal wire (3) and coupler (4) from generator

(5).

4) Remove adjusting bolt (1) and pivot bolts (2).

5) Remove generator.

INSTALLATION

Reverse above procedure giving specified tension to drive belt.

Refer to “Generator (Water Pump) Belt” for belt tension.

Tightening Torque

(a): 22 N·m (2.2 kg-m, 16.0 lb-ft)

(b): 50 N·m (5.0 kg-m, 36.5 lb-ft)

(c): 7 N·m (0.7 kg-m, 5.0 lb-ft)

6H-12 CHARGING SYSTEM

GENERATOR (WATER PUMP) BELT

BELT TENSION INSPECTION

1) Inspect belt cracks, cuts, deformation, wear and cleanliness.

2) Check belt for tension. Belt is in proper tension when it deflects

12 to 15 mm (0.47 – 0.59 in.) under thumb pressure (1) (about

10 kg or 22 lb.).

Belt tension “a” : 6 – 7 mm (0.24 – 0.28 in.) as deflection

NOTE:

When replacing belt with a new one, adjust belt tension to

5 – 6 mm (0.20 – 0.24 in.).

3) If belt is too tight or too loose, loosen adjusting bolt (2) and pivot

bolts (3) and adjust it to proper tension by displacing generator

(4) position.

4) Tighten generator adjusting bolt and pivot bolts.

Tightening Torque

(a): 22 N·m (2.2 kg-m, 16.0 lb-ft)

(b): 50 N·m (5.0 kg-m, 36.5 lb-ft)

5) Connect negative cable at battery terminal.

REMOVAL

1) Disconnect negative cable at battery.

2) Remove front bumper.

3) Loosen generator adjusting bolt (1) and generator pivot bolts

(2).

4) Slacken belt (3) by displacing generator and then remove it.

INSTALLATION

1) Install belt to water pump pulley, crankshaft pulley and genera-

tor pulley.

2) Adjust belt tension.

3) Tighten water pump belt adjusting bolt and pivot bolts.

4) Connect negative cable at battery.

CHARGING SYSTEM 6H-13

6H-14 CHARGING SYSTEM

UNIT REPAIR OVERHAUL

GENERATOR

1. Pulley nut

2. Pulley

3. Drive end frame

4. Stator

5. Stud bolt

6. Drive end bearing

7. Bearing retainer

8. Rotor

9. Bearing cover

10. End housing bearing

11. Bearing cover

12. Washer

13. Rear end frame

14. Rectifier

15. Insulator

16. Regulator

17. Brush

18. Brush holder

19. Rear end cover

20. Retainer plate screw

21. Rear end frame nut

22. Rear end frame bolt

23. Rectifier holder screw

24. B terminal inner nut

25. IC regulator screw

26. Brush holder screw

27. Rear end cover screw

: Tightening Torque

DISASSEMBLY

1) Remove B terminal inner nut (1) and insulator (2).

2) Remove 3 screws (3) and remove rear end cover (4).

3) Remove 2 screws (1) and pull out brush holder assembly (2).

4) Remove 3 screws (3) and IC regulator (4).

5) Remove brush holder cover from brush holder.

6) Remove rectifier holder screws (1).

7) Remove rectifier holder (2).

8) Hold shaft by using hexagonal box wrench and remove pulley

nut (1), and then pull out pulley (2).

CAUTION:

D To hold shaft, use hexagonal box. Duodecimal box

may cause slipping and consequential shaft or

tool damage.

D Do not attempt to hold pulley by using vise or pipe

wrench so as not to distort it.

9) Remove rear end frame nuts (3) and bolts (4).

10) Drive out rear end frame (1) with rotor tapping shaft (2) lightly

by using plastic hammer.

11) Separate rear end frame from rotor evenly by using plastic

hammer.

CAUTION:

Do not hit shaft at slip ring side, when separating ro-

tor and rear end frame.

CHARGING SYSTEM 6H-15

12) If required, use bearing puller (2) to remove end housing bear-

ing (1) and bearing cover (3).

CAUTION:

Care must be exercised so as not to distort cooling

fan blade while applying puller.

13) If required, remove 4 screws, retainer plate (1) and then drive

out drive end bearing (2).

14) If required, remove stud bolts and then pull out stator.

NOTE:

Heating drive end frame may facilitate removal of stator.

6H-16 CHARGING SYSTEM

INSPECTION

Rotor

Open Circuit

Using ohmmeter, check for continuity between slip rings of rotor

(1). If there is no continuity, replace rotor.

Standard resistance: About 2.9 W

Ground

Using ohmmeter, check that there is no continuity between slip ring

and rotor (1). If there is continuity, replace rotor.

Slip Rings

D Check slip rings for roughness or scoring. If rough or scored, re-

place rotor.

D Using a vernier caliper, measure slip ring diameter.

Standard diameter: 14.4 mm (0.567 in.)

Minimum diameter: 12.8 mm (0.504 in.)

If the diameter is less than minimum, replace the rotor.

Stator

Open Circuit

Using ohmmeter, check all leads for continuity. If there is no conti-

nuity, replace stator.

Ground

Using ohmmeter, check that there is no continuity between coil

leads and stator core. If there is continuity, replace stator.

CHARGING SYSTEM 6H-17

Brush

Exposed Brush Length

Check each brush for wear by measuring its length as shown. If

brush is found worn down to service limit, replace brush. Refer to

“Replace Brush” in this section.

Exposed brush length “a”

Standard : 10.5 mm (0.413 in.)

Limit : 1.5 mm (0.059 in.)

Rectifier

Positive Rectifier

1) Using an ohmmeter, connect one tester probe to the B terminal

(1) and the other to each rectifier terminal (2).

2) Reverse the polarity of tester probes and repeat step 1).

3) Check that one shows continuity and the other shows no conti-

nuity.

If there is continuity, replace rectifier holder.

Negative Rectifier

1) Using ohmmeter, connect one tester probe to each negative ter-

minal (1) and the other to each rectifier terminal (2).

2) Reverse the polarity of tester probes and repeat step 1).

3) Check that one shows continuity and the other shows no conti-

nuity.

If there is continuity, replace rectifier holder.

6H-18 CHARGING SYSTEM

Bearing

Drive End Bearing

Check that bearing is not rough or worn.

End Housing Bearing

Check that bearing is not rough or worn.

When removal is necessary, refer to disassembly of UNIT REPAIR

OVERHAUL.

REPLACE BRUSH

1) Unsolder and remove brush and spring.

2) Run wire of new brush through the hole in the brush holder, and

insert spring and brush into brush holder.

3) Solder brush wire to brush holder at specified exposed length.

Exposed length “a”: 10.5 mm (0.413 in.)

4) Check that brush moves smoothly in brush holder.

5) Cut off excess wire.

6) Apply insulation paint to the soldered area.

CHARGING SYSTEM 6H-19

ASSEMBLY

1) If end housing bearing (1) is removed, install it.

2) Check end housing bearing turns smoothly.

3) If stator (2) is removed, install stator and tighten stud bolts (1).

4) If drive end bearing (3) is removed, install it.

5) Check drive end bearing turns smoothly.

Tightening Torque

(a): 8.8 N

m (0.88 kg-m, 6.5 lb-ft)

(b): 2.6 N

m (0.26 kg-m, 2.0 lb-ft)

6) Place space collar and drive end frame (2) on pulley, and then

install rotor (1) to drive end frame.

7) Install rear end frame to drive end frame.

8) Tighten bolts and nuts to specified torque.

Tightening Torque

(a): 4.5 N

m (0.45 kg-m, 3.5 lb-ft)

9) Install pulley (1) and tighten pulley nut (2) with holding shaft us-

ing hexagonal box wrench to specified torque.

Tightening Torque

(a): 113 N

m (11.3 kg-m, 81.5 lb-ft)

6H-20 CHARGING SYSTEM

10) Install rectifier holder (1). Curl stator leads (2) as shown in fig-

ure.

CAUTION:

When installing rectifier, check to confirm that stator

leads have enough clearance with cooling fan

blades.

Tightening Torque

(a): 2.0 N

m (0.2 kg-m, 1.5 lb-ft)

11) Install brush holder cover to brush holder.

12) Place IC regulator (1) together with brush holder (2) horizon-

tally on rear end frame (3).

13) Install 5 screws.

Tightening Torque

(a): 2.0 N

m (0.2 kg-m, 1.5 lb-ft)

14) Install rear end cover (1).

Tightening Torque

(a): 3.7 N

m (0.37 kg-m, 3.0 lb-ft)

15) Install insulator (2) and tighten B terminal inner nut (3) to speci-

fied torque.

Tightening Torque

(b): 3.6 N

m (0.36 kg-m, 3.0 lb-ft)

16) Make sure that rotor turns smoothly.

CHARGING SYSTEM 6H-21

6H-22 CHARGING SYSTEM

SPECIFICATIONS

BATTERY

Rated capacity

28 AH/5 HR, 12 Volts

Electrolyte 2.5 L (5.28/4.40 US/lmp pt)

Electrolyte S.G. 1.24 when fully charged at 20_C (68_F)

GENERATOR

NOTE:

The generator used in each vehicle is one of the following two types, depending on specification.

Type 40 A type 50 A type

Rated voltage 12 V

Nominal output 40 A (at 13.5 V) 50 A (at 13.5 V)

Permissible max. speed 18,000 rpm

No-load speed 1,110 r/min (rpm)

Setting voltage 14.2 to 14.8 V

Permissible ambient temperature –30 to 90 _C (–22 to 194 _F)

Polarity Negative ground

Rotation Clockwise viewed from pulley side

Charging System for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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