BEST PRACTICES
BATTERIES
BATTERY MAINTENANCE
COMPLAINT & ORIGIN
1. PM B- Every 450 – 600 hours
 If the batteries show evidence of corrosion or if electrolyte is present on the outside of the battery, remove
the cables and clean the cable ends and battery post with a wire brush. With all accessories on, crank engine
and observe cranking operation.
 Check voltmeter and ampere charging system dash instruments.
2. PM C, every 6th Oil Drain,
 Test batteries – Check batteries with cables attach and record results. Remove and clean cables and battery
post and test batteries with cables unattached. Any difference noted will identify the loss due to corroded
cables. (See Mid-Tronics training material. (Vehicles with multiple batteries either in series or parallel are
illustrated in the appropriate addendum’s)
 Attach copies of the battery test to the PM forms.
Best Practices will be developed for only Prototype Vehicles
CONDITION - Vehicle operating normally, no driver complaints
DIAGNOSIS – General Diagnostics:
1. Visual Battery inspection and cranking operation (PM B)
2. Perform Battery Conductance Test (PM C)
3. Conduct general battery “State of Charge” Test (PM C)
4. Perform CCA Test (PM C)
5. Print out Battery test results and include in vehicle file.
REPAIR CODES ATA Code
Pm-001
PM-001
PM-003
TOTAL TIME
Mfg. Code
A08-T1
A08-T2
A08-T3
(ALL MODELS)
Procedure Description
Administrative Time Open/Close R.O.
Visual Battery Test/Cleaning (inc in PM B)
Test/Clean Batteries (EACH) PM C
Time Allowed
0.0
0.0
0.2
(National Fleet price included in Lease Rating System)
ATA Code
Part #
Description
PM, No parts required
Qty
Fleet Price
EPA (3%) & Supply Charges (5%) of labor charged
TYPICAL ACTION DESCRIPTION: During PM, observed corrosion on battery cables. Removed and cleaned cables.
WARRANTY: No Warranty for PM functions.
GENERAL COMMENTS – Effective Battery maintenance should include visual inspection of all battery cables and
connections. Starter connections should be examined for signs of overheating. Cables will be discolored indicating
overheating. This is particularly visible on the clip between the solenoid and the starter. Early detection can eliminate
costly road breakdowns.
Batteries 1
January 18, 1999
Parts @ National Fleet Prices in U.S. Dollars
BEST PRACTICES
BATTERIES
BATTERY REPLACEMENT
COMPLAINT & ORIGIN
1. PM B- Every 450 – 600 hours
 If the batteries show evidence of corrosion or if electrolyte is present on the outside of the battery, remove
the cables and clean the cable ends and battery post with a wire brush. With all accessories on, crank engine
and observe cranking operation.
 Check voltmeter and ampere charging system dash instruments.
2. PM C, every 6th Oil Drain,
3. Test batteries – Check batteries with cables attach and record results. Remove and clean cables and battery
post and test batteries with cables unattached. Any difference noted will identify the loss due to corroded cables.
(See Mid-Tronics training material. (Vehicles with multiple batteries either in series or parallel are illustrated
in the appropriate addendum’s)
4. Attach copies of the battery test to the PM forms.
5. Driver reports vehicle will not start.
Best Practices will be developed for only Prototype Vehicles
CONDITION - Truck will not crank
DIAGNOSIS –
1. Perform Battery Conductance Test (PM C)
2. Conduct general battery “State of Charge” Test (PM C)
3. Perform CCA Test (PM C)
4. Print out Battery test results and include in vehicle file.
REPAIR CODES –
ATA Code
Mfg. Code
32-001
32-001
32-001
32-001
32-001
32-001
32-001
32-001
TOTAL TIME
Procedure Description
A08-T1
Administrative Time Open/Close R.O.
A08-140
R&R First Battery (Includes test)
A08-141
R&R Each Additional Battery
A08-150
R&R Battery Ground Cable
A08-001
R&R Battery to Starter Cable
A08-170
R&R Battery to Battery Cable (one)
A08-170
R&R Battery to Battery Cable (Two)
A08-170
R&R Battery to Battery Cable (Three)
Time Allowed
0.4
0.5
0.2
0.3
0.7
0.3
0.4
0.5
(ALL MODELS)
(National Fleet price included in Lease Rating System)
ATA Code
32-001-001
32-001-001
Part #
ZBDMF24F60
ZBDMF31DSW
Description
Battery
Battery
Qty
1
1
Fleet Price
$ 44.12
$ 63.62
EPA (3%) & Supply Charges (5%) of labor charged
TYPICAL ACTION DESCRIPTION: Diagnosed Cranking System, Replaced bad battery
WARRANTY: 1 Year Unlimited miles parts and labor, Two year with Diamond Spec.
GENERAL COMMENTS – Each location should maintain a battery charging station with good ventilation. We recommend replacing all the
batteries in a vehicle if the test reflects a bad battery. All batteries removed should be cleaned and placed on a slow charge for 24 hours. Retest
batteries and return any battery, which continues to be defective. If a vehicle has one defective battery and there are batteries on the test stand
which match the requirements, replace the defective battery with a used battery. This procedure should be followed on all vehicles with less than
one year remaining in service. Install new batteries in vehicle with more than one year remaining in service.
Batteries 2
January 18, 1999
Parts @ National Fleet Prices in U.S. Dollars
BEST PRACTICES
BATTERIES
CHARGING SYSTEM MAINTENANCE
COMPLAINT & ORIGIN
1. PM B- Every 450 – 600 hours
 Visually check all mounting brackets, connections and instrumentation.
 Check voltmeter and ampere charging system dash instruments.
2. PM C, every 6th Oil Drain,
 Test Charging System (See page 11 of Mid-Tronics Miro500 Training Manual)
 Attach copies of charge system test to the PM form.
Best Practices will be developed for only Prototype Vehicles
CONDITION - Vehicle operating normally, no driver complaints
DIAGNOSIS – General Diagnostics:
1. Visual Inspection of all Alternator Brackets, connections and Belts
2. Perform Charging System Test (PM C)
 Test Charging System (See page 11 of Mid-Tronics Miro500 Training Manual)
 Attach copies of charge system test to the PM form.
REPAIR CODES ATA Code
Pm-001
PM-001
PM-003
TOTAL TIME
Mfg. Code
A08-T1
A08-T2
A08-T3
(ALL MODELS)
Procedure Description
Administrative Time Open/Close R.O.
Visual inspection (inc in PM B)
Test Charging System (PM C)
Time Allowed
0.0
0.0
0.2
(National Fleet price included in Lease Rating System)
ATA Code
Part #
Description
PM, No parts required
Qty
Fleet Price
EPA (3%) & Supply Charges (5%) of labor charged
TYPICAL ACTION DESCRIPTION: During PM, visually inspected alternator brackets, connections, and belts.
Observed instrument voltage and ampere output during In Cab Inspection. (PM C, Performed charging system test and
printed results for vehicle file.
WARRANTY: No Warranty for PM functions.
GENERAL COMMENTS – Effective charging system maintenance should include visual inspection of all charging
system components will eliminate many road failures and customer down time. One or two road failures caught during
the PM cycle will pay for the Mid-Tronic’s Analyzer.
Batteries 3
January 18, 1999
Parts @ National Fleet Prices in U.S. Dollars
BEST PRACTICES
BATTERIES
Alternator/Regulator Replacement
COMPLAINT & ORIGIN
1. PM B- Every 450 – 600 hours
 Visually check all mounting brackets, connections and instrumentation.
 Check voltmeter and ampere charging system dash instruments..
2. PM C, every 6th Oil Drain,
 Test Charging System (See page 11 of Mid-Tronics Miro500 Training Manual)
 Attach copies of charge system test to the PM form.
3. Driver IL-700 reports alternator not charging.
Best Practices will be developed for only Prototype Vehicles
CONDITION - Dead Batteries due to alternator failure
DIAGNOSIS – General Diagnostics:
1. Visual Inspection of all Alternator Brackets, connections and Belts
2. Perform Charging System Test (PM C)
 Test Charging System (See page 11 of Mid-Tronics Miro500 Training Manual)
 Attach copies of charge system test to the PM form.
3. Replace defective Alternator/Regulator
REPAIR CODES ATA Code
Pm-001
31-001
Mfg. Code
A08-T1
A08-100
TOTAL TIME
Procedure Description
Administrative Time Open/Close R.O.
R&R and/or Replace Alternator
Time Allowed
0.4
1.1
(ALL MODELS)
(National Fleet price included in Lease Rating System)
ATA Code
31-002-001
31-002-001
31-002-001
31-002-001
Part #
8LHA2054UA
8LHA2241VA
BLD2305
BLD2308
Description
Alternator 110 A
Alternator 130 A
Brushless Alternator 140 A
Brushless Alternator 160 A
Qty
1
1
1
1
Fleet Price
$159.49
$184.93
$345.32
$381.67
EPA (3%) & Supply Charges (5%) of labor charged
TYPICAL ACTION DESCRIPTION: During PM, visually inspected alternator brackets, connections, and belts.
Observed instrument voltage and ampere output during In Cab Inspection. (PM C, Performed charging system test and
printed results for vehicle file.
WARRANTY: No Warranty for PM functions. International Warranty 1 year, 2 years, with Diamond Spec
(Unlimited miles/Kilometers) Extended coverage from Leece-Neville, 3 years, 350,000/560,000
miles/kilometers. (Parts & Labor) See Warranty Bulletin 99-003G Coverage includes only BLD, BLP series
(Brushless) Alternators. Leece-Neville LBA, LBP series (Long Brush) 2 years, 250,000 miles. Leece-Neville
will replace the unit that qualify for warranty with a new unit..
GENERAL COMMENTS – Effective charging system maintenance should include visual inspection of all charging
system components will eliminate many road failures and customer down time. One or two failures caught during the
PM cycle will pay for the Mid-Tronics Analyzer.
Batteries 4
January 18, 1999
Parts @ National Fleet Prices in U.S. Dollars
BEST PRACTICES
BATTERIES
CRANKING SYSTEM MAINTENANCE
COMPLAINT & ORIGIN
1. PM B- Every 450 – 600 hours
 Visually check all Starter mounting, connections, etc.
 Test Starter with lights and accessories on.
2. PM C, every 6th Oil Drain,
 Test Cranking System (See page 10 of Mid-Tronic’s Micro500 Training Manual)
 Attach copies of cranking system test to the PM form.
Best Practices will be developed for only Prototype Vehicles
CONDITION - Vehicle operating normally, no driver complaints
DIAGNOSIS – General Diagnostics:
1. Visual Inspection of starter and related components
2. Perform Cranking System Test (PM C)
 Test Cranking System (See page 10 of Mid-Tronics Micro500 Training Manual)
 Attach copies of cranking system test to the PM form.
REPAIR CODES ATA Code
Pm-001
PM-001
PM-003
TOTAL TIME
Mfg. Code
A08-T1
A08-T2
A08-T3
(ALL MODELS)
Procedure Description
Administrative Time Open/Close R.O.
Visual inspection (inc in PM B)
Test Cranking System (PM C)
Time Allowed
0.0
0.0
0.2
(National Fleet price included in Lease Rating System)
ATA Code
Part #
Description
PM, No parts required
Qty
Fleet Price
EPA (3%) & Supply Charges (5%) of labor charged
TYPICAL ACTION DESCRIPTION: During PM, visually inspected Starter, connections, and belts and related
components (PM C, Performed cranking system test and printed results for vehicle file.
WARRANTY: No Warranty for PM functions.
GENERAL COMMENTS – Effective cranking system maintenance should include visual inspection of all charging
system components will eliminate many road failures and customer down time. One or two road failures caught during
the PM cycle will pay for the Mid-Tronic’s Analyzer.
Batteries 5
January 18, 1999
Parts @ National Fleet Prices in U.S. Dollars
BEST PRACTICES
BATTERIES
Starter Replacement
COMPLAINT & ORIGIN
1. PM B- Every 450 – 600 hours
 Visually check Starter mounting, connections, etc
 Test Starter with lights and accessories on.
2. PM C, every 6th Oil Drain,
 Test Cranking System (See page 10 of Mid-Tronics Micro500 Training Manual)
 Attach copies of cranking system test to the PM form.
3. Driver IL-700 reports Starter will not crank.
Best Practices will be developed for only Prototype Vehicles
CONDITION - Batteries in good condition but starter will not crank
DIAGNOSIS – General Diagnostics:
1. Visual Inspection of starter and related components
2. Perform Cranking System Test (PM C)
 Test Cranking System (See page 10 of Mid-Tronics Micro500 Training Manual)
 Attach copies of cranking system test to the PM form.
3. Batteries checked and in good condition, fully charged.
REPAIR CODES ATA Code
Pm-001
32-002
32-002
32-002
Mfg. Code
A08-T1
A08-220
A08-250
A08-240
TOTAL TIME
Procedure Description
Administrative Time Open/Close R.O.
R&R and/or Replace Starting Motor
R&R Starter Relay Switch
R&R Starter Solenoid Switch
Time Allowed
0.4
1.4
0.9
1.9
(ALL MODELS)
(National Fleet price included in Lease Rating System)
ATA Code
32-002-001
32-002-001
32-002-001
32-002-001
32-002-001
32-002-001
Part #
M100R Series
M100R Series
MS2 Series
MS2 Series
MS2 Series
MS2 Series
Description
Starter (Medium Duty)
Starter (Medium Duty) w/ Overcrank Protection
Starter (530 Engine Only)
Starter (530 Engine Only) w/ Overcrank Protection
Starter (Heavy Duty)
Starter (Heavy Duty) w/ Overcrank Protection
Qty
1
1
1
1
1
1
Fleet Price
$172.83
$190.42
$263.25
$282.26
$251.63
$270.16
EPA (3%) & Supply Charges (5%) of labor charged
TYPICAL ACTION DESCRIPTION: During PM, visually inspected starter mounting and connections. (PM C,
Performed cranking system test and printed results for vehicle file. Replaced defective starter, relay and/or solenoid)
WARRANTY: No Warranty for PM functions. International Warranty 1 year, 2 years, with Diamond Spec
(Unlimited miles/Kilometers) Extended coverage from Leece Neville, 3 years, 350,000/560,000
miles/kilometers. (Parts & Labor) See Warranty Bulletin 99-003G
GENERAL COMMENTS – Effective cranking system maintenance should include visual inspection of all charging
system components will eliminate many road failures and customer down time. One or two failures caught during the
PM cycle will pay for the Mid-Tronics Analyzer.
Batteries 6
January 18, 1999
Parts @ National Fleet Prices in U.S. Dollars