15–00 Safety Precautions
Safety Precautions in this section apply to all
procedures within this group.
DANGER
When working on the vehicle, shut down the en-
gine or motor, set the parking brake, and chock
the tires. Before working under the vehicle, always
place jack stands under the frame rails to ensure
the vehicle cannot drop. Failure to follow these
steps could result in serious personal injury or
death.
15–01 Alternator, Battery, and
Starter Connections
Check
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 Group
15 of the 108SD and 114SD Workshop Manual.
3. Inspect the alternator drive belt for cracking,
glazing, and wear; see
Group 01. Replace the
belt if it shows any of these symptoms.
NOTE: Engines equipped with a serpentine belt
have automatic belt tensioners, and do not re-
quire 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 alter-
nator and starter are free of corrosion. Clean and
tighten all charging system electrical connec-
tions, 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 ex-
posed 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 Group 54 of the
108SD and 114SD Workshop Manual for trouble-
shooting instructions, and for adjustment, repair,
and replacement instructions.
8.1 Inspect the battery cables, and replace
any that are damaged.
8.2 Clean and tighten the battery ground
cables, terminals, and clamps. Clean the
cable connector terminals with a wire
brush.
8.3 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).
8.4 Coat the battery terminals and cable con-
nections with dielectric grease.
9. Check the connections at the power net distribu-
tion box. Clean and protect the power cables
with dielectric enamel as necessary.
Alternators and Starters 15
108SD and 114SD Maintenance Manual, September 2015 15/1
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