freightliner Custom Classic MT45 2022 Maintenance Manual page 41

Alternators and Starters
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 release explosive gas as a by-product of
their chemical activity. Do not smoke when work-
ing around batteries. Put out all flames and re-
move any source of sparks or intense heat. Make
sure the battery compartment is 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 bat-
teries.
Damaged, chafed, or kinked wiring can cause
electrical short-circuits and lead to fires, causing
property damage, injury, or death. Clean, inspect,
and maintain wiring and connections carefully.
1. Disconnect the batteries.
2. Check the tightness of the alternator bracket fas-
teners and alternator mounting fasteners; tighten
the fasteners as needed. For torque values, see
Group 15 of the vehicle Workshop Manual, or
take the vehicle to an authorized Freightliner
dealer.
3. Check that all electrical connections at the alter-
nator and starter are clean. Clean and tighten all
charging system electrical connections as
Walk-In Van Chassis Maintenance Manual, July 2015
needed. Spray each electrical connection at the
alternator and starter with dielectric red enamel.
Trace and inspect all wiring and cables con-
nected to:
• alternator
• starter and depopulation studs
• batteries
• magnetic switch
• cab
• jump-start studs
• battery isolation relays
• battery shutoff switches
4. Check wires and cables for wear, chafing, kinks,
discolored insulation, or loose clamps or ties.
Find the cause of any problems and repair, re-
place, and reroute wires and clamps as neces-
sary.
IMPORTANT: Ensure that wires and cables are
not near any heat sources; if they are, reroute
them.
5. Clean all circuit breakers and relays.
6. Check the alternator wiring for missing insulation,
kinks, and heat damage. Replace or repair as
needed.
7. On the bundled cable that runs from the batteries
to the starter, ensure that tie straps are installed
at least every 12 inches (30 cm). Replace any
missing tie straps, and add tie straps where
spacing between them exceeds 12 inches (30
cm).
8. Ensure that all cables have sufficient slack to
allow for engine movement, and that there is no
force on any wiring connectors.
9. If any convoluted tubing is damaged, check the
wiring inside it. Replace any damaged or missing
convoluted tubing.
10. Inspect the battery cables for wear, and replace
as needed. Clean the cable connector terminals
with a wire brush. See Group 54 of the vehicle
Workshop Manual for troubleshooting instruc-
tions, and for adjustment, repair, or replacement
instructions, or take the vehicle to an authorized
Freightliner dealer.
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