Alternator, Battery, and Starter Connections Check

sd mm 15.01.001

    Warning: Batteries generate explosive gas as a by-product of their chemical process. Do not smoke when working around batteries. Put out all flames and remove any source of sparks or intense heat in the vicinity of the battery compartment. Make sure the battery compartment has been completely vented before disconnecting or connecting the battery cables.

    Battery acid is extremely harmful if splashed in the eyes or on the skin. Always wear a face shield and protective clothing when working around batteries.

  1. Disconnect the batteries.
  2. Check the tightness of the alternator fasteners; tighten as needed. For torque values, see  of the 108SD and 114SD Workshop Manual.
  3. Inspect the alternator drive belt for cracking, glazing, and wear; see Safety Precautions. Replace the belt if it shows any of these symptoms.

    4. Note: Engines equipped with a serpentine belt have automatic belt tensioners, and do not require belt tension adjustment.

  4. Check the alternator wiring for missing insulation, kinks, and heat damage. Replace or repair as needed.
  5. Check that all electrical connections at the alternator and starter are free of corrosion. Clean and tighten all charging system electrical connections, including the connections at the starter B+ terminal and ground terminals, the magnetic switch, and where the alternator charging cables terminate. Apply red dielectric enamel to all exposed connections.
  6. Inspect the battery retainer assembly or hold-downs, and the battery box. Replace worn or damaged parts. Remove any corrosion with a wire brush, and wash with a weak solution of baking soda and water. Flush with clean water, and dry. Paint the retainer assembly if needed, to prevent rusting.
  7. Check that foreign material, such as road debris, is removed from the battery box.
  8. Inspect and clean the battery cables, terminals, and clamps as follows. See  of the 108SD and 114SD Workshop Manual for troubleshooting instructions, and for adjustment, repair, and replacement instructions.
    1. Inspect the battery cables, and replace any that are damaged.
    2. Clean and tighten the battery ground cables, terminals, and clamps. Clean the cable connector terminals with a wire brush.
    3. Connect the cables to the batteries and tighten them to the torque specifications listed on the battery, generally 10 to 15 lbf·ft (14 to 20 N·m).
    4. Coat the battery terminals and cable connections with dielectric grease.
  9. Check the connections at the power net distribution box. Clean and protect the power cables with dielectric enamel as necessary.
Note:
Parent topic: Alternators and Starters
Document Number: 0000119706
Manual Publication Date: 2024-05-23
Topic Publication Date: 2024-10-30