Chevrolet Repair: HELP!! failure of charging system on 97 SUBURBAN, battery cables, ground cable


Question
Hello Van,
Recently I replaced the tensioner, alternator (after it failed) and serpentine belt on a '97 Suburban 1500 4WD.  Since the battery was dead, the battery was given a "shot" to get the car started.  Subsequently, the charging system failed again.  I installed another alternator and replaced the battery.  When installing the alternator, I disconnected the battery.  Unfortunately, the battery cable came in contact with the battery terminal.  The wire that connects to the back of the alternator got fried (causing a deterioration of one-third of the connector that gets screwed to the alternator).  Now, the charging system (despite a new battery and new alternator) continues to fail after running for 15 minutes.  The gauge shows the battery at 9 to 10 and the truck doesn't start.

I have checked fuses, but they are OK.
1.) What diagnostic should be done to identify the problem?
2.) Would this possibly be a wiring issue or a damaged fusable link?
3.) If it is wiring, can a new connector be added to the large wire that attaches to the alternator or does it require a complete replacement of the battery cables?

The only way to get the truck to a shop is to replace the battery (or have it towed).  Will running it on a new battery be OK or will it cause further damage?

Thanks for your help.  I'm feeling kind of stupid since I can't seem to solve this problem!  Greatly appreciate your advice!  Bubba

Answer
Well, Bubba, come on now...don't feel stupid. After all, you are at least willing to attempt your own repairs.
Now, for the wire end...yes, you can get one and stick it on there. Doesn't even need the rubber cover over it, as long as it doesn't touch anything except the bolt that it is supposed to be on.
While doing the work, make sure the ground cable is off the battery.
If the short there burned that wire end, it could also have damaged something back along that wire, like another connector. But, ultimately, that wire goes directly to the battery positive, even if it is on the starter bolt.
Driving the truck on a new battery to the shop won't hurt anything.
Now...the SHOT you refer to interests me...what, exactly, is a SHOT?
If you did something like jump it with a battery charger that puts out a high voltage, you could concievably cause damage to the charging system, as well as the electronic systems, so I don't recommend using those booster chargers to crank the engine.
Luckily, your voltage regulator is inside the alternator, so it can all be tested, and replaced, together, if needed.
Van