Alternator Positive Terminal Melted

The plastic in the insulating block was badly melted however the cable eye terminal was just a little dirty. just another jackass ford employee. First, here's a link to a thread that helps describe my problem: Alternator Positive Lead Melting I'm updating this with new pics, and I hope some of y'all can help me out with getting me back on the road. We highly recommend you take a Digital Multi-Meter and measure the resistance of your newly installed cables before connecting the negative battery cable. The new alternator configuration slightly different, but as best I can tell I’ve wired it correctly. For a few weeks, my voltmeter has been showing low voltage with the engine running, anywhere from 12-13. The positive battery terminal is directly connected to the alternator, and it can be dangerous to work on if it's live (see Project 84). that doesn't start when it gets wet (yeah I've been shopping for a new one). To check circuit between alternator B+ (output) terminal and the positive battery terminal perform a voltage drop test. Happened after running it for twenty ish minutes shutting it off and trying to restart and hour later. Assorted Lugs and screws. A fusible link will be along the cable(s) running between the positive terminal of the battery and the battery terminal of the alternator. BAD GROUNDS. • Never use a Mega-Ohm tester on an alternator. To connect the terminal ends, seat the positive terminal followed by the negative terminal. Figured it out fixed it immediately, new eyelets (back of alternator and the positive box, as well as a new) Problem solved. This style boot is typically used to cover a ring terminal or lug on an alternator or starter. Reconnect the ground cable, start the engine and using a VOM meter, verify that the alternator is charging at least 13. Battery was either not fully charged, always use a Harley battery, or terminals were not tight enough (most likely the cause when positive side melts ). Reconnect the positive battery cable, start the engine and using a VOM meter, verify that the alternator is. i brought the alternator into hedahl's (auto parts store) today and it tested fine. I guess in the event of a short and things starting to melt, disconnecting the negative terminal will have the same end result as disconnecting the positive, but can someone explain the pros and cons o. the connections to find a melted connector. With the engine running and the headlights on, there should be less than half a volt voltage drop, and ideally less than one-tenth of a volt drop. The alternator supplies electrical current when the engine is running. Length is 350 mm, which should work for just about any battery/relay installation. MAKE SURE THAT THE BATTERY IS FULLY CHARGED. There was no way the alternator would come straight up on mine. From C-7, the yellow wire goes to Electric Fuel Pump Cut Relay #1. **NOW Repeat This Test Again, BUT: 1) Connect the Voltmeter Directly Across the Positive Terminal of the Starter and it Case Ground. The source of electricity must have two terminals: a positive terminal and a negative terminal. Fig 5 - Alternator Leakage Current To check alternator diode leakage, connect the multimeter in series with the alternator output terminal when. A Short Course on Charging Systems by Charles Ofria. The insulation on them may even melt. Is the ignition switch open? If all of the fusible links in the ignition run. Most Balmar alternators are case grounded, i. 2 volts, then start your car and rev the engine to 2,000 RPM. Alternator Positive Terminal Melted On Sale. strange electrical issues, but the car starts, not unlocking, randomly, the ignition clattering on startup, other manufacturers, when the battery dies, the car is dead. new JEGS 1 -wire alternator and re-tension the drive belts. Polka Dot Images/Polka Dot/Getty Images. To connect the terminal ends, seat the positive terminal followed by the negative terminal. I bought another terminal connector and put it on, and it melted again (after about 3 weeks). Install airbox and cruise control unit. alternator, install the alternator and re-tension the drive belts. One wire alternators eliminate the unsightly factory wiring harness and simplifies installation by using only one wire for charging. We have come across our fair share of electrical demons with Jeeps over the years and figured we'd bring you The top 10 Jeep electrical Problems and Cures. The battery cables are tight and in good shape. If the cable end melts, replace the entire ground cable and be sure that you have clean bright contact bolts & unpainted contact areas. That can stress your charging system and cause early. I took my 1997 Yamaha 1100 waverunner out for a spin and after about 200 or 300 yds it cut out. Look for scraping, rubbing, bare wires, burn spots or melted plastic. Fusible links can sometimes be difficult to recognize, so be sure to check the entire length of cable for soft spots, or melted insulation. to tell you the truth i didnt fuse iti might later on when i get some more 0 gauge crimps. It doesnt matter if the positive is on first or negative. if I touched the part of the terminal that had the charging wire off the alternator hooked to it it would start welding. One thing to be aware of is that some sources show the output terminal as B+. On a Toyota, they have all kinds of death knock. Step #10 Start engine and test alternator. Measure the current from the positive side to the negative side with a voltometer. Popped the hood to check the battery connections and burnt my fingers on the positive battery cable/terminal. Forum discussion: I'll post pics tonite, but I wanted to get your take on how/why the positive terminal of my battery would be so hot, that you'd recoil in pain after having your finger on it for. i was out at the time and my brother's battery had gone flat. Remove the battery negative terminal clamp and then the positive terminal clamp. Pull the connectors apart and carefully inspect the terminals (the metal parts) inside the connectors. The following information is presented as a guide when wiring and troubleshooting alternators. The alternator is new, and was replaced several months ago. Smaller gauge terminals are universal and the same terminal can be used with either the'+' or '-' side of your battery. Negative battery wire and post getting hot - posted in Virtual Mechanic: Anyone have any ideas as to why my negative battery cable is getting so hot while the engine is running? Any help appreciated. Connect the carbon pile tester positive lead to the B+ stud (output terminal) on the alternator. The PX-8150 Kit, below on the left, supports only the positive. Melted battery Terminal, starter wiring confusion, HELP!? Hi everyone, me and a friend of mine just finished a clutch job on my 1983 944, and when we went to start her up, the positive battery terminal melted, and there was an unhealthy amount of smoke from the battery. Battery terminals come in either positive or negative polarity for use with either the positive post or negative post of your battery. A Short Course on Charging Systems by Charles Ofria. The two grey wires are two 12 awg fusible links in parallel. As a result, if the generator is not polarized to a positive charge and positive current is sent into the terminals, the generator can be damaged as well as the other motors and switches on the same current. A person can boost a battery using a Pontiac G5 or Pursuit by connecting the positive leads to the positive battery terminal and the negative lead to a strong ground like the alternator bracket. It could have been much worse than some melted wires. Install washers under the bolt heads and under the nuts, see next step too. Suppose there's a good circuit from the alternator output terminal (BAT) over to the positive battery terminal and the alternator is properly grounded. alternator, but someone probably makes one. Looking for the right Battery Terminal Cover today? Find your next Battery Terminal Cover and other auto parts and accessories for sale on Ebay today. If there is no '+' terminal on your alternator, but there is a 'B+', then it may well be the output. Sealed, waterproof, fully insulated, tin soldering ring, heat shrink tube. A hole was melted in the rear cover. Then, secure them by tightening each bolt. Upon installing the new battery once I hooked up the negative battery terminal it melted a 10 gauge black wire running to the back side of the alternator. Does that heavy positive wire to the alternator look at all overheated? Especially check the voltage drop between the positive post of the battery and the wire terminal connector to it. (and actually a battery sensed alternator because with the machine sensed 70amp alternator the brown wire is tied back and not used. 60 amp alternator too high? Page 2 of 3 [ 38 posts ] Go to page Previous 1 2 3 Next Previous topic | Next topic : Author Message; emsvitil. Reconnect the positive bat-tery cable, start the engine and using a VOM meter, verify that the alternator is charging at least 13. The symptoms might start out being minor, but they could progressively get worse if you don’t do anything about the ground wire. There are two heavy black and one yellow wire from the alternator that come together into one fusible link wire, which is connected to the same terminal that the positive cable of the battery goes to on a relay? that's next to the battery. it appears that it is only getting hot when the rig dont want to start right away and longer cranking happens. We apologize that this item is not available for pickup in store at this time. I’m new to this forum. As a result, if the generator is not polarized to a positive charge and positive current is sent into the terminals, the generator can be damaged as well as the other motors and switches on the same current. Terminal, Battery Positive. Thing is the stock alternator I took out didn't over charge and worked, and the Escalade alternator that I have in it now works perfectly like it is suppose to, so I'm figuring that somehow. I may try home depot, but no auto stores in my area have a crimping tool that can apply the force needed for a stereo-grade 4 guage ring terminal. If you need to, use some copper washers underneath the ring terminal to help it seat properly, the factory connector is small and tabbed so that it will fit inside the plastic insulator. Therefore, if voltage at BAT is 14. : any chassis location) with DMM negative lead. New Alternator, melted fuse block and 4 volts VW MKIV-A4 TDIs (VE and PD) www. R #1 Simply connect one wire from the positive battery terminal to the positive alternator terminal. It had melted on the bottom side and dripped onto the battery, burning a hole into the battery. tery terminal and the alterna- tor is properly grounded. I tried an 8 guage ring terminal (Circuit City), but it was too small for the wire. Augment this with a wire from one of the alternator mounting bolts to the vehicle frame. The yellow S wire is melted only from the T plug on the alternator to fuse link splice. I can't figure out how the battery wiring work. The alternator B+ feed should be fused at a minimum of 150% of the alternators output rating. Reconnect the battery. For this reason, most people recommend connecting the positive to the battery and then the negative to the car ground - either a designed point by the manufacturer or the engine lift hook if available. 5 volts when I hit the gas, and 15v idling. Looking for the right Battery Terminal Cover today? Find your next Battery Terminal Cover and other auto parts and accessories for sale on Ebay today. The 2011 Jeep Grand Cherokee has 10 problems reported for alternator blown. Therefore, if voltage at BAT is 14. This item is extremely nice product. One connection must go to the regulated voltage from the VR, the other must find ground, and if you have an electronic regulator, I would expect you to have two wire in the harness for field connections. , terminal voltage will fall on removing the full-load. I was driving this weekend and smell some thing like cable burning. I’ve had an inquiry about converting from a Lucas dynamo to a Delco 10-SI alternator. The big wire coming off my positive terminal is a #8 and it goes to the starter motor and then on to the battery bank. Connect the negative lead to the positive battery terminal. It is sometimes referred to as Toyota Battery Terminal. I ended up pulling a used post/bracket from a junk yard and mounted that without changing out the alternator. Stator voltage on a healthy alternator is one-half charging voltage, plus or minus about. Replace cables that are questionable with factory style cables. it appears that it is only getting hot when the rig dont want to start right away and longer cranking happens. There is a outfit called Quality Power that offers a 6 volt, 60A positive ground alternator based on a GM single wire unit for $135. #3 after 80A fuse it seems like heavy wire to Starter Motor is connected directly to Battery , Not through current sensor. Voltmeter (-) test lead to the battery (+) post. But you know people learn from their. The final test you can run is doing a reverse circuit test where you do not remove the cables from the devices they are connected to and then test between the battery terminal and the device. Chuck: R1. The Alternator. Any difference in reading indicates a poor connection somewhere in the red cable from the alternator. I can't swear to this, but I think I have seen alternators still charging with a blown ignition light. Install new alternator onto bracket using hardware provided. Remove the drive belt (A) after turning the drive belt tensioner (B) counterclockwise. You are not replacing anything. Hey I had the positive terminal connector wire melt when I replaced it yesterday. Our Product Is Made Of High Quality Brass , The Conductivity Is Good. Terminal, Battery Positive. Hence regulation is negative in such cases. It could have been much worse than some melted wires. Got it in my shop and come to find out the positive power feed from the back of the alternator melted completely off the battery post, as well as the positive wire that goes to the grid heater relays. I want to get all these added on and "hotwire" circuits off the alternator and get the wiring off the engine. to the battery. This has happened twice In the past month. That means. The green terminal does have a release lever that must be squeezed to get it. CarComplaints. 2003 dodge cummins. I'd be REAL suspicious of the (+) cable on the starter - maybe a dyno tie-down hitting it or compressing the suspension with strapping tight, etc. Positive & Negative battery terminals. The beauty of the one wire alternator design is it's very simple to hook up, just run a charge wire from the positive battery terminal (or battery side of shutoff switch) to the stud terminal on the alternator. The range is 240 volt electric 3 wire hooked up to a 40 amp breaker (6 gauge wire). Make sure you have the proper size ring terminal, use a wire brush to clean the alternator stud and nut. The alternator supplies electrical current when the engine is running. The other circuits are located in a single connector and are responsible for controlling the voltage regulator located within the alternator. I suspect a faulty alternator again. Won't make that mistake again. #1 Positive Battery Terminal itself #2 between 80A fuse and Current sensor. The starter and alternator ground carries the same current as the positive voltage hot leads to or from the starter or alternator. ) Test your new alternator by using your voltmeter and touching the positive voltmeter wire to the positive terminal on the back of the alternator; touch the negative voltmeter wire to the negative battery terminal in the engine compartment. You can disconnect the battery cables, negative then positive, and scrub the terminal posts and connectors with a mixture of baking soda and water to remove the corrosion. The rotor in an alternator contains a field coil or field windings, which are powered by the regulator via the brushes. It's that easy! #1 (Left terminal) NO. A careful inspection for any signs of powdery white or blue corrosion anywhere on the terminal or along the cable can reveal if there is a problem. Reply 1: Is there a diagram of the positive. Connects to a switched 12 volt source. Truck Harness Plug NOT USED 1 X2 Two Wire Connection without Tach D+ Terminal B+ Terminal Truck Harness Plug NOT USED 1 2 R X Three Wire Connection with Tach D+ Terminal Tachometer (W) B+ Terminal. To melt the terminals it would take a lot of heat I have seen them do that with a high cranking amp battery and over cranking a bike that wouldn't start. Stator voltage on a healthy alternator is one-half charging voltage, plus or minus about. negative cable on alternator. VN Commodore Alternator. This wire is a voltage reference to the alternator. Find where the positive goes through the firewall and make sure it's not getting sliced up. I ended up pulling a used post/bracket from a junk yard and mounted that without changing out the alternator. The insulation on them may even melt. Now, connect the wire from battery positive (+) terminal to your alternator. Something caused a very fast discharge of that battery (especially as it is "well fried"!). Positive Terminal getting Hot!? 2005 Dodge Neon SXT. There are only 3 wires to add: 1 ADD a 4 gauge wire to the positive lug at the back of the alternator, (the lug is under the black rubber boot at the lef t rear of the alternator. Two wire: Alternators that have two wires connected to them are self excite. Voltmeter (+) test lead to the alternator output terminal. ) Wizard Radiator/Fan combo I've removed the fan electric from consideration right now to focus on the core problem. 6 Volt Alternator found in: 63 Amp One Wire Alternator with Pulley -- Used for converting 6 Volt to 12 Volt, Electronic Ignition Kit: Ford 6 Volt Positive Ground, 6 Volt to 12 Volt Conversion FAQs - Antique Tractor Blog, Ammeter. If you have continuity then it is not an isolated ground engine and you can use any alternator, otherwise you have to use an special isolated ground alternator. Sympton: Battery slowly goes dead, but ammeter sometimes shows a positive charge. I assume the PO upgraded the wiring in anticipation of an alternator upgrade but never got around to installing the upgraded unit. One wire is white and it follows a path to the battery positive terminal. You see this happen a lot with the headlamp high beam terminal connectors which typically goes bad when the metal becomes overheated. Stock Alternator. Problems will be encountered with the original Lucas 'helmet style' clamps, as the battery posts are sized (the larger one is the positive post). Now my positive battery terminal clamp has disintegrated. Battery, starter, and alternator is really the only 3 "exposed" areas for high-current, always hot, terminals. Use a voltmeter instead to conduct a simple, safe test. The alternator is new, and was replaced several months ago. Continuity is good. The source of electricity (whether it is a generator, battery or something else) will want to push electrons out of its negative terminal at a certain voltage. Install seat, if removed. 5 A is provided to the relay coil, using a high side driver, between R terminal and L terminal, after a time delay of 300 µs. While the ground is “built into” its engine mount, we recommend that a second- ary ground cable be added to the ground terminal (if equipped) at the back of the alternator. Battery was either not fully charged, always use a Harley battery, or terminals were not tight enough (most likely the cause when positive side melts ). Look for scraping, rubbing, bare wires, burn spots or melted plastic. They are designed to melt before something gets damaged. Replace cables that are questionable with factory style cables. 3 volts charge from the alternator. Charging system gauge or warning lamp. he said he couldn't find the wire on the computer and insisted that it was part of the main harness, which it is. The wire at the back of the alternator melted off the eyelet, and the wire was scorched, even under the boot. What is a Charging System? The modern charging system hasn't changed much in over 40. An overcharging alternator would have to be extreme to produce that high current. That is not some kind of sixties hippie movement, but rather the practice of connecting the plus terminal of the car’s battery to the chassis as common ground. The two grey wires are two 12 awg fusible links in parallel. If it is a big chafe, with steady contact to the frame, you'll get a dead short from the battery back through the wire. An "A" terminal, which is the output of the alternator, which also is connected to the positive terminal of the battery. Colour coded for easy polarity identification Two sizes available. The Negative Cable \“Sparked\” when I connected it to the Battery Terminal and the 10 AWG Wire from the Positive Battery Cable started to smoke and melt. Is your wiring harness a mess? Weird assortments of wires, different colours spliced to different other colours, half-dissolved electrical tape streaming in the wind?. Your alternator needs to be charging at or above 14 volts at 2000 RPM. How to Test the Alternator on a Craftsman Riding Lawn Mower A multimeter allows you to test the current, voltage and resistance of numerous types of equipment. Used For Updated Alternator Combined Cancer/Birth Defect WARNING This product can expose you to chemicals including Cadmium which is known to the State of California to cause cancer, birth defects or other reproductive harm. You must have at least. Connects to the positive (+) terminal of the coil. Those are the same whether it's in START or RUN, so RUN would blow the fuse, and it doesn't, at least by my reading of R1's writing. Many times we'll find the connector melted and the terminals black from extreme heat. the connections to find a melted connector. can cause high. com : Car complaints, car problems and defect information. To excite the positive ground alternator you run a jumper from the case (positive power) to the #1 spade terminal on the alternator. Protects terminals from electrical shorts and shocks. Choosing a Backup Generator Plus 3 LEGAL House Connection Options - Transfer Switch and More - Duration: 12:39. Fusible links can sometimes be difficult to recognize, so be sure to check the entire length of cable for soft spots, or melted insulation. My buddy chuck told me that there must be a leak somewheremaybe where the positive cable runs to the starteror somewhere where the positive might be hitting a ground somewhere. I've been having an issue with the positive terminal on my alternator for over a year now. alternator probably has two large spade terminals, as mentioned fi+fl and fiSfl, these are both the same and can improve your system by putting in an additional cable between the spade terminal on the alternator and the starter solenoid. Reconnect the positive bat-tery cable, start the engine and using a VOM meter, verify that the alternator is charging at least 13. The car seemed fine, I only noticed it because I needed to borrow the battery for a different volvo and that car ran it fine. as far as the smoke, I'm going to guess that when that happens, the wire gets. Figure 1 — N1609 Alternator and Regulator Terminals AC terminal IGN terminal B+ connections on alternator Both positive cables must be connected together at battery posi-tive potential when alternator is installed in vehicle and during operation. I got out and the positive terminal bolt melted out of my redtop's inset battery terminal. Old, frayed cable ends may have exposed wires, which will cause arcing to other metal parts, resulting in a melted battery terminal. Application. The guide is likely to be similar for any brand ammeter. Note that the 2004+ police cruisers witht the 200amp alternator will have two 10 awg fuselinks in parallel, rather than 12 awg fuselinks. We have come across our fair share of electrical demons with Jeeps over the years and figured we'd bring you The top 10 Jeep electrical Problems and Cures. With a charged battery, the car should. Using a short wire, jump S terminal to ALT 'B' terminal The correct way to do it is to make the jumper wire the same length as the ALT wire (as per the factory diagram below),. This wire can go directly to the battery, or it can connect to some point that is equivalent to the positive terminal of the battery. It looks like a conversion, as there is an unused bracket near the alternator that I presume was used for attaching the generator. #3 after 80A fuse it seems like heavy wire to Starter Motor is connected directly to Battery , Not through current sensor. Suspect everything is OK. With the engine running and the headlights on, there should be less than half a volt voltage drop, and ideally less than one-tenth of a volt drop. I had the new alternator checked while on the truck again and it still showed a bad voltage regulator while the testing machine was attached to the battery terminal. 5 vdc at idle but within specs at high rpm you need to check the idle speed. Forum discussion: I'll post pics tonite, but I wanted to get your take on how/why the positive terminal of my battery would be so hot, that you'd recoil in pain after having your finger on it for. Understanding the Alternator • Four wires connect the alternator to the rest of the charging system. Left Positive upgraded 3/0 battery to starter cable for improved Cold Weather/Hard Start performance with loom. Please remember that any wires leading to the house bank will get fused at the banks positive terminal or within 7" of it. The 100 amp alternator has a ground wire running from the alternator case to the engine block/alternator bracketry. Find Alternator Wiring Kits and get Free Shipping on Orders Over $99 at Summit Racing! 10 ft. and are backed by the manufacturer's 12 month, 12,000 mile warranty. on these W124's, the alternator isn't wired directly to the battery, its wired to a 'positive terminal' near the battery. Please remember that any wires leading to the house bank, or another +12V source, will get fused at the banks positive terminal or within 7″ of it. The Negative Cable \“Sparked\” when I connected it to the Battery Terminal and the 10 AWG Wire from the Positive Battery Cable started to smoke and melt. Define terminal. terminals on the battery, the negative to the chassis and or engine and the positive is going direct to the starter solenoid and ignition switch. just another jackass ford employee. Low charge: This problem can occur if the belt is slipping or if the engine rpm is too low. To excite the positive ground alternator you run a jumper from the case (positive power) to the #1 spade terminal on the alternator. All the consumers are protected with fuses, these are not the culprit. They also offer a nice adaptor bracket that makes mounting the alternator very straightforward. Decide on the location of the Portable. There is a 10-guage wire between the battery Positive terminal and the output of the generator. You are not replacing anything. Protects terminals from electrical shorts and shocks. However Ford is claiming that my VIN is not part of the recall, even though it is specific for my model and year, and even though my car is experiencing the exact issue that the recall is for: faulty. In this position, all en-ergy going into and coming out of the battery must pass through the shunt. The starter and alternator are normally the two highest current devices in a vehicle's electrical system. Terminal Definition Notes A BATTERY Comes from the word ‘Accumulator’ B BATTERY Main Battery Feed B+ BATTERY Main Battery Feed C CENTRE Neutral, ‘Half-Voltage’, centre point of a Y-connected stator. If you have easy access to the alternator without getting your body parts / clothing / etc tangled in the spinning pulley’s, then place the positive multi-meter probe (red) and touch it to the red terminal connector coming out of the alternator. 93 gmc 3500 diesel dually. negative cable on alternator. On the solenoid this extra cable should be connected to the same terminal as the main battery. The battery positive lead connects to this terminal via a ring terminal connector, with the nut holding it in place. 75,000 MilesIt has the original Battery, but it reads fine on the Fluke. The battery cables are tight and in good shape. Attach the original B+ cable to the B+ terminal of the new Bosch alternator. We had a spare fully charged battery at the house so my brother thinking that he knew what he was doing. See if they look burned or have a green tint indicating corrosion. I tried an 8 guage ring terminal (Circuit City), but it was too small for the wire. The Combiner is attached to the positive terminal of each bat-tery bank and to ground. I've also had a problem that caused the same symptoms - it was the battery terminal connections. Used For Updated Alternator Combined Cancer/Birth Defect WARNING This product can expose you to chemicals including Cadmium which is known to the State of California to cause cancer, birth defects or other reproductive harm. Connect the other end of the black lead to the positive battery terminal. Maybe a bad voltage regulator or alternator? I don't want to put another battery in a melt it too. In many cases the alternator shares the battery cables from the starter to the batteries. In some cases the alternator is wired directly to the batteries. Many times we’ll find the connector melted and the terminals black from extreme heat. I had to wait for a month for the new alternator, finally the new alt was mounted but four days later it died again and my car passed away on the middle of the highway. In 1986 GM introduced the completely new, 105-amp, CS130 Delcotron alternator (CS130 = Charging System with 130mm diameter stator) because the SI alternators could not keep up with the increased electrical demand and because overdrive transmissions were lowering engine and alternator rpms. That will result in melted insulation, smoke, bad smells, and maybe fire. tried to jump my car and the jumper cables melted! WHAT does it mean?!?!?! - posted in Lifestyle & Off Topic: My car is a P. Well it died again last week, I thought the wire had just come out of the little push on eyelet thing, I was wrong. Popped the hood and the positive terminal cable connector was glowing red. A generator, unlike an alternator, can run off both positive and negative current. ALTERNATOR TEST 1: Testing Battery Voltage With The Engine Running. When that happens, it's necessary to replace them. Wear eye protection and rubber gloves. In both cases, overlap the repair about 1/2-inch on either side. Your ground from the battery to the engine block, and the positive terminal on the alternator to the disconnected positive cable on the battery should measure less than one ohm. The positive terminal will have a + sign on it and usually a red wire running to it. If it is a fusible link wire, replacing it with a regular wire could cause more damage or even a fire. Suspect everything is OK. While engine is at idle, take a screwdriver or pocket knife and place on the back of the alternator bearing surface, (the round area in. Install fan guard assembly (6) on alternator (9) with three bushings (8), washers (5), and capscrews (4). 61 Alternator charge indicator B+ Battery positive terminal B– Battery negative terminal D+ Alternator positive terminal D– Alternator negative terminal DF Alternator field winding DF1 Alternator field winding 1 DF2 Alternator field winding 2 U, V, W Three-phase terminals Audio systems 75 Radio, cigarette lighter 76 Loudspeaker Switches. I may try home depot, but no auto stores in my area have a crimping tool that can apply the force needed for a stereo-grade 4 guage ring terminal. The cutoff switch must remove all electric power from the battery and alternator (except a fire suppression system must remain powered). Looked to be some smoke damage on the alternator and the B+ post cover had completely melted. (and actually a battery sensed alternator because with the machine sensed 70amp alternator the brown wire is tied back and not used. Re: Melted positive Battery Terminal It got hot because of the voltage drop caused by the bad connection at the battery. I checked locally, the fusible link from the alternator and the insulating block both had to be ordered. Does that heavy positive wire to the alternator look at all overheated? Especially check the voltage drop between the positive post of the battery and the wire terminal connector to it. The positive battery terminal is directly connected to the alternator, and it can be dangerous to work on if it's live (see Project 84). You can run the charge lead from the alternator directly to the battery positive terminal through a dedicated and appropriately sized fusible link. If you own a First Generation Ford Mustang and if you are still driving around with your stock alternator or generator wires, you could run into a problem sooner or later. The alternator B+ feed should be fused at a minimum of 150% of the alternators output rating. I use a Balmar ARS 5 regulator. 1964-1977 Chevelle Alternator Positive Terminal Cap And Retainer Kit Red Product May Vary From Above Listed Image This is a new reproduction red plastic GM style alternator positive terminal cap and retainer kit. There is a plug with four wires, starting with the big wire (it has the larger of the four pins) they are: S - connect this right to the "+" stud on the alternator with a ring terminal (big wire) F - Not needed. That said, now when I start the car it runs smoothly, but in less than a minute the wire from the alternator to the voltage regulator heats up to the point that it is melting. A good alternator should measure less than. This crystal radio offers the spring terminals and only a small handful of components. Polarize the generator. Connect the negative to a good ground on the bike. I disconnected the battery. The negative terminal has the excess electrons (electrons are negatively charged) and the electrons flow from the negative side of the battery to the positive side, to fill in the lack of electrons on the positive side. Voltmeter (+) test lead to the alternator output terminal. That will result in melted insulation, smoke, bad smells, and maybe fire. The voltage might be a little higher at the alternator B+ (output) terminal than at the battery positive terminal—and if so, it's probably a little higher than optimal for feeding lamps—but no voltage spikes are present in an electrical system with good voltage regulation, and any spikes that are present in a system with bad voltage. See if they look burned or have a green tint indicating corrosion. Melted battery Terminal, starter wiring confusion, HELP!? Hi everyone, me and a friend of mine just finished a clutch job on my 1983 944, and when we went to start her up, the positive battery terminal melted, and there was an unhealthy amount of smoke from the battery. The positive terminal on my battery is connected to the starter relay. It could have been much worse than some melted wires. Install airbox and cruise control unit. This time, the positive wiring seems to have been damaged. I think it does not get its initial excitation via the warning light it's via the IG terminal. Many times we'll find the connector melted and the terminals black from extreme heat. I can't figure out how the battery wiring work. The separate battery charging wire was routed directly from the alternator to the battery POSITIVE cable. The resulting heat from the loose connection melted the brass output post and aluminum rear housing.