freightliner PE116DC, Maintenance Manual

Page: 37 / 164

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 bracket fas-
teners; tighten the fasteners as needed. For
torque values, see
Group 15 of the New Casca-
dia ™ Workshop Manual .
3. Check that all electrical connections at the alter-
nator and starter are clean. Clean and tighten all
charging system electrical connections, including
the connections at the starter B terminal and
ground terminal, and where the alternator charg-
ing cable terminates.
4. Inspect the battery cables for wear, and replace
them if they are damaged. Clean the cable con-
nector terminals with a wire brush. See
Group
54 of the New Cascadia
™
Workshop Manual for
adjustment, repair, or replacement instructions.
4.1 Clean and tighten the battery ground
cable, terminal, and clamps.
4.2 Inspect the retainer assembly or battery
hold-downs, and the battery box. Replace
worn or damaged parts. Remove any cor-
rosion 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.
4.3 Check that foreign objects, such as
stones, bolts, and nuts, are removed from
the battery box.
4.4 After cleaning, connect the cables to the
batteries and tighten them to the torque
specifications listed on the battery, gener-
ally 10 to 15 lbf·ft (14 to 20 N·m).
4.5 Coat the battery terminals with dielectric
grease.
5. Check the alternator wiring for missing insulation,
kinks, and heat damage. Replace or repair as
needed.
6. Check the terminals on the battery shut-off
switch and the magnetic switch. Make sure the
terminal connections are clean and tight. Coat
the terminal connections with dielectric red
enamel after cleaning.
Alternators and Starters
15
New Cascadia Maintenance Manual, January 2017
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