15–01 Alternator, Battery, and
Starter Checking
1.
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
School Bus Chassis Workshop
Manual
.
2.
Check that all electrical connections at the alter-
nator and starter are clean. Clean and tighten all
charging system electrical connections as
needed.
3.
Check the alternator wiring for missing insulation,
kinks, and heat damage. Replace or repair as
needed.
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 bat-
teries.
4.
Inspect the battery cables for wear, and replace
as needed. Clean the cable connector terminals
with a wire brush. See Group 54 of the
School
Bus Chassis Workshop Manual
for troubleshoot-
ing instructions, and 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.
Rinse 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
Spray each connection with dielectric red
enamel and coat the battery terminals
with dielectric grease; see
Approved Dielectric Protectants
Protectant Material
Approved Brand
Dielectric Grease
Lubriplate FLP DS–ES
Dielectric Red Enamel
Spray-On Application
3M 1602 IVI-Spray Sealer; order
from the PDC
Spray-On B–6–665
Dielectric Red Enamel
Brush-On Application
Gyptal 1201EW-Low VOC, Red;
order at www.glyptal.com or
1-800-GLP-1201
Table 1, Approved Dielectric Protectants
5.
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
Alternators and Starters
15
School Bus Chassis Maintenance Manual, January 1999
15/1
