Freightliner Business Class. Manual - part 11

Title of Maintenance Operation (MOP)

MOP Number

Alternator, Battery, and Starter Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–01

Alternator and Starter

Index, Alphabetical

Business Class Trucks Maintenance Manual, January 2004

15–01 Alternator, Battery, and

Starter Checking

WARNING

Batteries release a gas mixture that is explosive.
Do not smoke when working around batteries. Put
out all flames, and remove any source of sparks
or intense heat. Make sure the battery compart-
ment has been completely vented before discon-
necting or connecting battery cables.

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

Check the tightness of the alternator bracket fas-
teners; tighten the fasteners as needed. For
torque values, see Group 15 of the

Business

Class

Trucks Service Manual

Check the belt tension of the alternator drive
belt. Use a tension gauge at the belt’s widest
span, and adjust the belt tension if needed. See

Group 01

in this manual for belt tension specifi-

cations. Some Caterpillar engines are equipped
with dual alternator belts. Always check both
belts for correct tension. Engines equipped with
a serpentine, or poly-V belt have automatic belt
tensioners and do not require belt tension in-
spection.

Check that all electrical connections at the alter-
nator and starter are clean. Clean and tighten all
charging system electrical connections as
needed.

On the bundled cable running from the batteries
to the starter, ensure that tie-straps are installed
at least every 12 inches (300 mm). Replace any
missing tie-straps and add tie-straps where spac-
ing between straps exceeds 12 inches (300 mm).

Ensure that all cables have sufficient slack to
allow for engine movement and that there is no
pressure on any wiring connectors.

Check all wiring inside of damaged convoluted
tubing and replace any damaged or missing con-
voluted tubing.

Inspect the battery cables for wear, and replace
as needed. Clean the cable connector terminals

with a wire brush. See Group 54 of the

Business

Class

Trucks Service Manual

for troubleshoot-

ing instructions, and for adjustment, repair, or
replacement instructions.

7.1

Clean and tighten the battery ground
cable, terminal, and clamps.

7.2

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.
Rinse with clean water, and dry. Paint the
retainer assembly, if needed, to prevent
rusting.

7.3

Check that foreign objects, such as
stones, bolts, and nuts are removed from
the battery box.

7.4

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).

7.5

Spray each connection with dielectric red
enamel and coat the battery terminals
with dielectric grease; see

Table 1

Protectant Material

Approved Brand

Dielectric Grease

Lubriplate FLP DS–ES

Dielectric Red Enamel

Spray

3M 1602 IVI-Spray Sealer

Spray-On B–6–665

Table 1, Approved Dielectric Protectants

Check the alternator wiring for missing insulation,
kinks, and heat damage. Replace or repair as
needed.

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; see

Table 1

Alternator and Starter

Business Class Trucks Maintenance Manual, January 2004

15/1

Title of Maintenance Operation (MOP)

MOP Number

Fan Clutch Checking (Noise Emission Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–03

Radiator Cap Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–01

Radiator Pressure Flushing and Coolant Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–02

Engine Cooling/Radiator

Index, Alphabetical

Business Class Trucks Maintenance Manual, August 2003

20–01 Radiator Cap Checking

WARNING

Do not remove or loosen the radiator cap until the
engine and cooling system have completely
cooled. Use extreme care when removing the cap.
A sudden release of pressure from removing the
cap prior to the system cooling can result in a
surge of scalding coolant that could cause seri-
ous personal injury.

CAUTION

The radiator cap currently installed may not be the
same one installed when the vehicle was built. If
the radiator cap must be replaced, make sure that
it is the correct cap for the cooling system of the
vehicle. Because the radiator cap pressure rating
affects the operating temperature of the engine,
installing an improperly rated radiator cap may
have adverse effects on the cooling system, and
engine operating temperatures. This could cause
premature engine wear or damage.

Using a radiator-cap tester, check the pressure
cap to see if it maintains pressure to within 10%
of the pressure rating marked on the cap. If it
doesn’t, replace the cap. Make sure that the re-
placement radiator cap is correctly rated for the
cooling system of the vehicle.

There is a second valve in the radiator cap that
opens under vacuum. This prevents the collapse
of hoses and other parts that are not internally
supported when the system cools. Inspect the
vacuum-relief valve to be sure it is not stuck.

Make sure that the cap seals properly on the
coolant filler neck seat, and that the radiator cap
gasket is not damaged. On vehicles with screw
on caps with O-rings, make sure that the O-ring
is not cracked or deteriorated. Replace the cap if
the gasket shows deterioration or damage.

20–02 Radiator Pressure

Flushing and Coolant
Changing

NOTE: For additional instructions on cleaning
and flushing the cooling system, see the engine
manufacturer’s maintenance and operation
manual.

Drain the radiator.

1.1

Remove the surge tank cap. See

Fig. 1

1.2

Open the petcock at the bottom of the
radiator to drain the engine coolant. See

Fig. 2

Disconnect the radiator inlet and outlet hose con-
nections.

Flush the radiator.

3.1

Attach a flushing gun nozzle to the radia-
tor outlet.

3.2

Run water in until the radiator is full.

3.3

Apply no more than 20 psi (138 kPa) air
pressure intermittently to help dislodge
sediment buildup in the core.

f500107a

11/19/94

Surge Tank

Fig. 1, Surge Tank and Cap

Engine Cooling/Radiator

Business Class Trucks Maintenance Manual, August 2003

20/1

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