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Foreword
Table of contents
Introduction - Charging systems
Charging system in a motor vehicle
Lesson 1 - Alternator
Variable that influence electricity generation
Alternator components
Rotor
Stator
Rectifier
Voltage regulator
Charge warning light
Suzuki charging systems
Alternator symptom diagnosis
On vehicle diagnosis
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5
5
6
7
7
8
9
12
13
14
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Lesson 2 Battery
Battery construction
Effects of temperature on electrolyte
Chemical reactions inside the battery
Battery ratings
Maintenance-free batteries
Battery maintenance & testing
Battery charging
Jumpstarting a discharged battery
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Alternator
Battery
Charge warning light (in instrument cluster)
Wiring harness
Function
Alternator
When the magnet is moved in and out of the coil, the needle of
the galvanometer moves to the left or right depending on the
direction of movement of the bar magnet.
Click on the illustration to view an animation.
Figure 1
[a] Galvanometer
[b] Magnet
[c] Coil
a
Figure 2 Alternator
Suzuki Kizashi
Operating principles
The alternator generates electrical energy by using the
principles of electromagnetic induction. When an electrical
moves relative to the lines of force of a magnetic field, a
voltage is induced in the conductor. According the Faradays
law, the induced voltage increases when the speed of the
vertical motion or size of the magnetic flux is increased. In the
simple illustration below, a permanent magnet moves in and
out of a coil. The coil ends are connected to a galvanometer.
EN05 Engine Auxiliary System I Charging system
+
v
of
180
360
540
720
Figure 4
[V] Voltage
[] angle of rotation
rotor
Temperature
The process of conversion of mechanical energy to electrical energy
causes the components of the alternator to heat up. Alternators are
often cooled by means of a fan or in some cases, alternators can be
water cooled. Ambient temperature also affects the production of
electricity by the alternator.
Example: the table below illustrates the effects of temperature on
output voltage of the alternator (Suzuki Kizashi A6B424)
Figure 6
[a] Output voltage
[b] Regulator case temperature
[c] High output alternator
[d] Low output alternator
Alternator components
The alternator is made up of the following main components:
Rotor
Stator
Voltage regulator
Rectifier
Pulley
Bearings
Front and rear frames
Fan
Rotor
The rotor is an electromagnet that rotates inside the stator.
Current to energise the rotor is supplied by the battery via the
slip rings. The rotor is made up of a coil of wire wrapped
around and iron core. When current flows in the coil, a
magnetic field is created around the core. The coil is
surrounded by two claw type finger poles.
The magnetic field created saturates around the finger poles
and one becomes north and the other one south. When the
rotor is rotating, an alternating North, South, North, South
magnetic field is created. This magnetic field of different
poles cuts through the stator winding, resulting in AC being
induced in the stator windings.
Figure 8
[a] winding
[b] Claw pole
[c] Slip rings
Stator
Stator windings
Figure 9
[a] Stator winding
[b] Stator core
[c] Winging ends
Figure 9 Stator
Rectifier
The rectifier is made up of power diodes. Diodes are
semiconductor devices that allow current to flow in the
forward direction and block current flowing in the reverse
direction.
In a rectifier with 6 diodes (figure 12), three diodes are
negative diodes and other three diodes are positive diodes.
The positive diodes are connected to B+.
The rectifier uses these diodes to convert the alternating
current (AC) generated in the stator to direct current (DC),
suitable for the electrical system and battery charging.
Figure 13 Rectifier (bottom side)
Full-wave rectification
Rectification of Alternating Current
Half-wave rectification
In the following circuit (figure 14), a diode is connected in
series with an AC voltage supply. In this case, the diode will
allow the positive side of the AC voltage to pass and block the
negative side of the AC voltage. This results in a half wave as
illustrated in the graph.
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Figure 17
[2] IC voltage regulator
[3] Alternator
[4] Rotor
[5] Stator
Figure 16(a) Resultant wave pattern
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Voltage regulator
12
13
Figure 22
[1] Alternator
[2] IC regulator
[3] Stator winding
[4] Rectifier
[5] Rotor
[6] Charge warning light
[7] Ignition switch
[8] Battery
[9] Electrical loads
[10] BCM
[11] Combination meter
[12] CAN driver
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Operation
Engine control module (13) controls the output voltage of the
alternator using the C terminal based on the following
information:
Engine condition (ECT, vehicle speed, engine speed, TP, etc.
(14))
Battery voltage (ECM backup power voltage (15))
Electric load condition (blower motor, rear defogger, A/C,
headlights, etc. (16))
FR terminal output (field coil control duty) which indicates
the electricity generation rate of the alternator.
Then the IC regulator uses the C terminal duty cycle from the
ECM to adjust the current to the slip rings thus the output
voltage (B+ terminal voltage). The generated current is also
sent to the ECM via the FR terminal in duty cycle forms.
Figure 22
[1] Alternator [2] IC regulator [3] Stator coil [4] Diode
[5] Rotor [6] Charge warning light [7] Ignition switch [8]
[8] Battery [9] Electric load [10] BCM [11] IC [12] CAN driver
[13] Engine control module
This method of alternator control results in more accurately
controlled charge rate, allowing for smaller and lighter
batteries to be used. The module can also monitor system
operation to simplify diagnosis and repair by producing DTCs.
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The SDT can be used to monitor the actual duty cycles of the C
and FR terminals. This function is available under ECM data list.
F terminal
This parameter indicates operating rate (status of production
electricity) for generator by field coil duty ratio.
100%: maximum operation
0%: minimum operation
Terminal L and IG
The light control terminal L controls operation of the warning
light in the instrument cluster and the IG terminal is used to
supply power to the IC regulator (2) when the ignition is
switched ON.
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On-vehicle diagnosis
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Summary
The charging system is made up of the alternator, battery,
wiring harness, charge warning light.
The alternator is a generator that converts mechanical
energy to electrical energy and it is driven by the crankshaft
via a drive belt connected to the crankshaft pulley.
The IC regulator in the ECM controlled type adjusts the
alternator generated voltage based on a duty signal from the
ECM.
The charge warning light in the instrument cluster monitors
the alternator output voltage. If this drops below the
specified range, the warning light will be illuminated with the
engine running
Alternator on-vehicle tests can be performed to determine
the functionality of the charging system.
An inductive pick-up type ammeter must be used to measure
the charging current.
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Lesson 2
Battery
Objectives
At the end of this lesson, you will be able to:
Describe safety precautions that must be followed when
working with batteries.
Explain the operating principles of the lead-acid battery
Describe the basic parts of the battery
Describe the procedure to be followed when jumpstarting a
discharged battery
Describe the basic tests that must be performed on a battery
to determine its serviceability
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Battery
The automotive battery is an electrochemical storage facility
for electrical energy. The electrical energy stored by the
battery is needed during vehicle operation . When the engine
is running, the batterys electrical energy is used when the
electrical energy generated by the alternator is less than the
requirements of the electrical consumers in the vehicle. When
the engine is switched off, the battery supplies all electrical
consumers with electrical energy.
The three main functions of the battery are:
Supply power to the starter and ignition system so that
engine can be started
Acts as a voltage stabilizer in the electrical system by
damping voltage peaks to protect sensitive electronic
components
Supplement the electrical load when load requirements
exceed the alternator output.
EN05 Engine Auxiliary System I Charging system
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Battery construction
Battery case
The battery case is made of acid resistant material and is
subdivided into 6 cells by partitions. The cells contain positive
and negative plates as well as separators.
The top of the battery case (lid) also has the battery terminal
posts and an opening with a lid for each battery cell. Some
battery cases are also translucent and have the marking MIN
level and Max level which enables checking of the battery
electrolyte level without removing the battery caps.
Figure 4 Battery case
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Battery terminals
Plates
Plate separators
The negative and positive plates are placed very close to each
other. To prevent short circuiting of the plates, a non
conductor material is used to separate the plates.
Figure 7 battery separator [1]
Figure 5 SG indicator
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Battery cables
The battery hold down clamps and the battery tray keep the
battery mounted securely to the vehicle. This prevents
excessive vibrations of the battery that may cause physical
damage to the battery casing.
Electrolyte
Figure 8 Battery hold down clamp [2]
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Battery ratings
Amp-hour rating
The Amp-hour rating of a battery is the amount of current (in
Amps) the battery can supply for 20 hours before its voltage
drops below 10.5V.
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Description
(In the JIS standard, categories are set based on the width
and the box height)
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3 = Length
4 = Polarity position
This indicates the positive and negative polarity
position of the battery (R. or L. or no symbol). In the
R type, the negative terminal is located on the right.
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Safety precautions
Battery Sulfation
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.
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Battery care
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Battery testing
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Volt reading
% of charge
12.6 V
100
12.4 V
75
12.2 V
50
12.0 V
25
11.9 V
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Load test
The battery load test measures the batterys ability to deliver
adequate cranking power.
To perform a load test, first ensure that the batterys open
circuit voltage is above 12.4V. If lower than 12.4V, the battery
must be recharged first.
Use a suitable battery load tester and follow the
manufacturers instruction. To load test a batter, follow the
following general procedure applies.
1. After you have confirmed the open circuit voltage is above
12.4V, connect the load tester as shown on the diagram below.
2. Load the battery using the current load knob on the tester.
Max load current must be equal to 3 times the batterys Ah
rating or 1/2 the CCA rating.
3. Load test the battery for not more that 15 seconds
4. Record the voltage reading of the voltmeter,
9.6 V or higher : Good battery
9.5 V or lower : Replace battery
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Hydrometer test
State of charge
Temperature correction
As mentioned earlier in this lesson, temperature affects the
specific gravity of electrolyte. The SG reading is specified at
an electrolyte temperature of 20C.
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Surface discharge
Sulfuric acid and dirt on top of the battery case will lead to
current leakage. Perform the following test to determine
surface leakage. Place negative cable of voltmeter lead on
negative pole and move the positive lead on top of the battery
case.
To do the test;
1. Set a digital Multimeter to the Volts scale
2. Place the red probe of the Multimeter on the battery terminal
post
3. Place the battery negative terminal on the battery cable
4. Crank the vehicle with the ignition disabled and observe the
voltage reading. If the reading is above 0 Volts, clean the
battery posts and battery cables and retest
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Battery charging
It is impossible for the alternator to charge a discharged
battery adequately, therefore a battery charger must always be
used.
Precautions
1. Do not connect or disconnect the charger cables to the
battery whilst the charger is turned ON
2. Always charge a battery in a well ventilated area
3. Always wear safety gear when working with batteries
4. Open battery caps when charging
5. No open flames around battery charging station
6. Do not leave batteries on charge unattended (e.g. leaving a
battery on charge over night is unsafe)
7. Do not charge a battery whilst its still connected to the
vehicles electrical system
8. Periodically check the charge level of the battery to
determine if further charging is necessary.
Fast charge
Fast charging of a battery must be done in emergency
situations. This forces a larger amount of current through the
battery therefore frequently check the temperature of the
battery. Do not let the temperature exceed 52C. When fast
charging a battery, set the charging current to about 15% of
the batterys AH rating. Do not exceed 35A. A fast charge
must always be followed by a slow charge.
Slow charge
A slow charger forces only a small amount of current through
the battery. To slow charge a battery, set the batter charger
current to approximately 10% of the battery's Ah rating.
Periodically check the charge status of the battery to prevent
overcharging.
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Procedure
[1] Set parking brake and place gear shift lever in P position
(A/T model) or Neutral (M/T model). Turn OFF ignition switch,
lighting switch and all other electrical loads.
[2] Check electrolyte level. If below low level line, add
distilled water
[3] Attach end of one jumper cable to positive terminal of
booster battery and other end of same cable to positive
terminal of discharged battery. (Always use a 12V battery)
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Summary
A vehicle battery produces electrical energy through
chemical reactions.
The battery also acts as storage for electrical energy
Electrolyte is a mixture of sulfuric acid and distilled water
Maintenance batteries do not have openings to service the
electrolyte.
Always wear safety clothing and observe safety precautions
when working on a battery.
Each battery has a rating that indicates its capacity. This is
specifically important when the battery is being replaced.
The batteries used in Suzuki vehicles as original equipment
has the JIS type ratings.
Several tests can be carried out to determine the
serviceability of the battery, these include: Sulfation test,
surface discharge test, open voltage test, hydrometer test,
current drain test.
When jumpstarting, always follow the correct jumpstarting
procedure to prevent damage to the vehicles electronic
control units.
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