DELCOREMY.

COM

DIAGNOSTIC
PROCEDURES
MANUAL
For Starters
and Alternators
TABLE OF CONTENTS
SECTION PAGE

I) Introduction and Description

1–1. Introduction 1
1–7. Description 1
1–12. Electrical Fundamentals 2

II ) Diagnosis Charts
2–1. Overcharge Symptoms 8
2–2. Undercharge Symptoms 9
2–3. Milled Pinion Symptoms 10

III ) Testing
3–1. Testing Freedom Batteries 11
3–4. Testing Conventional Batteries 11
3–5. Test Procedure 12
3–7. Battery Cable Test with Single-Battery Location 12
3–10. Battery Cable Test with Dual-Battery Locations 14
3–13. Starter Solenoid Circuit Test 14
3–18. Magnetic Switch Circuit Test 16
3–21. Starter Replacement Determination 17
3–26. Alternator Wiring Test 18
3–29. Alternator Replacement Determination 19
3–33. Completion of All Tests 20

IV ) Summary

V) Appendix
5–1. Smart IMS or SIMS Diagnostic Steps 22
5-2. Overcrank Protection (OCP) Circuit Check 23
5-3. Multi-Battery Charging with Series and Parallel Chargers 23
5-4. Group Charging on Current-Limiting or Series Chargers 24
5-5. Group Charging on Voltage-Limiting or Parallel Chargers 24
5-6. Heavy Duty Diagnostics Procedures Data 25

PAGE 2
 SECTION I

INTRODUCTION AND DESCRIPTION

1-1. INTRODUCTION 1-5. For educational purposes, study of this entire manual is
recommended. For diagnostic purposes, the flow charts in Section II
1-2. PURPOSE. This manual provides diagnostic procedures that can be
will reference appropriate procedures for specific symptoms.
used for troubleshooting a heavy duty electrical system, including
the starting and charging systems. Some procedures also may be 1-6. EQUIPMENT REQUIRED. To perform the tests specified in this manual,
used for preventative maintenance checks. These procedures are the following equipment is required:
applicable to systems using heavy duty starters such as: Delco Remy
1. A variable carbon pile load tester with more than 500 amps
28MT™, 29MT TM, 31MT™, 35MT TM, 37MT TM, 38MT TM, 39MT TM,
capacity with ammeter (and voltmeter).
41MT TM, 42MT TM, 50MT TM or a similar starter with adequate
battery power for the engine/starter application used. 2. A separate DC voltmeter, digital preferred, capable of reading
0.01 volt increments.
1-3. DEFINITION OF DIAGNOSIS. Diagnosis is the three-part process that
begins when a problem is perceived and ends when the equipment 3. An inductive (clamp-on) ammeter for safe and accurate current
is confirmed as serviceable. Three questions must be answered to measurements.
assure completion:
4. A hand held or bench top type tester.
1. What are the symptoms? This is what has been observed (seen,
heard, felt or smelled), indicating a problem. 1-7. DESCRIPTION
2. What caused the symptoms? Diagnostic procedures are used 1-8. SYSTEM. The heavy duty electrical system is comprised of the
to identify the root cause of the problem. starting and charging systems. These systems are, in turn, comprised
of batteries, the starter, the alternator, and the interconnecting
3. How do we fix it? Usually this involves the adjustment, repair or
wiring and electrical and mechanical switches. For maximum
replacement of some part or parts.
operating efficiency, all parts of the system must be functioning
1-4. This manual defines the procedures to determine the cause of properly.
the symptoms. Actual adjustment, repair and replacement procedures
are provided in unit-specific service bulletins and manuals.

5
6
1

1. BATTERY
2. STARTER
3. ALTERNATOR 4
4. MAGNETIC SWITCH
5. PUSH BUTTON SWITCH
6. KEY SWITCH

2
DP-1001

FIGURE 1-1. Heavy Duty Electrical System

DELCOREMY.COM PAGE 1
1-9. BATTERIES. Batteries are perishable devices that wear out at some 1. Voltage. Voltage is the electrical pressure or force that causes
point in time. With use, they deteriorate and eventually become current or electrons to flow through a conductor. The voltage
incapable of performing their important job. In addition, new also can be described as the difference in electrical pressure
batteries may become discharged for various reasons. Neither worn between two points in a circuit. This electrical force or pressure
out nor discharged batteries can supply the power necessary for is measured in volts.
cranking. Thus, the battery check becomes the starting point for
diagnosing electrical system problems. 2. Current. Electrical current is the flow or movement of electrons
in a conductor. This movement can be compared to the flow
1-10. SUBCIRCUITS. Because of vibration, corrosion, temperature of water through a pipe. Without pressure (voltage), the current
changes or damage, the performance of wiring, connections and will not flow. Electrical flow is measured in amperes, most often
secondary components as well as the function of the starter and abbreviated as amps.
alternator can deteriorate. This, in turn, can cause malfunctions
within the starting and charging systems. For the purpose of testing,
wiring and components are divided into four circuits that must be
MAGNETIC FIELD
tested. These are:

1. Cranking Circuit. This consists of the large cables that carry

the high starter current. Excessive loss here causes slow
cranking speeds, especially in cold weather. Inability to start from
slow cranking can lead to starter damage if the starter is cranked
over 30 seconds. Deeply discharged or worn-out batteries also
can cause the same problem.

2. Solenoid Circuit. This consists of the wiring from the battery,

CURRENT DP-1005
through a push button or magnetic switch, to the S terminal of
the starter solenoid, and back to the battery. Excessive loss here
can cause the solenoid to shift in and out (chatter), resulting in 3. Resistance. Resistance is the opposition to current flow. For a
a no-start condition. This can cause a damaged contact disc and given electrical pressure (voltage), resistance decreases current
terminals of the starter solenoid. Deeply discharged batteries flow. This can be detected by voltage loss or drops in the
also can cause this problem. electrical circuit. Electrical resistance is measured in ohms.

3. Magnetic Switch Circuit or IMS (when the magnetic switch 4. Magnetic Field. When electrical current flows through a
is used). This consists of the wiring from the battery, through a conductor, a magnetic field is produced around the conductor.
key switch and/or start button, to the coil of the magnetic switch, By measuring the strength of this magnetic field, it is possible
and back to the battery. Excessive loss here can cause a “no to determine the amount of the current flow or amperage. This
start” complaint. principle is the basis for the function of the clamp-on or induction
type ammeter.
4. Charging Circuit. This consists of the wiring between the
alternator and the battery and back to the alternator. Excessive 1-14. MEASURING VOLTAGE WITH THE VOLTMETER. The voltmeter is used to
loss here can cause the batteries to not charge properly. As measure electrical pressure or voltage. The unit of measure is the
noted above, discharged batteries will cause other problems. volt. Voltmeters are always connected across (in parallel with) a part
of the electrical circuit (See Figures 1-6 and 1-7). The voltmeter
1-11. SEQUENCE OF PROCEDURES. It is important that these procedures measures the difference in electrical potential or pressure between
be followed in the exact sequence specified. Batteries, wiring and the points where the voltmeter is attached.
connections should be checked and corrected to the specifications
given. If cranking problems still occur, then connecting cables 1-15. VOLTMETER SELECTION. Voltmeters for the purposes described in this
should be checked before replacing the starter with a known good manual are DC instruments with a range as follows:
unit. Similarly, in the charging circuit, the batteries, wiring and 1. Low scale: 0-3 volts
connections should be thoroughly checked and corrected to the
2. 12-volt vehicles: 0-16 volts
specifications given. Only then should the alternator be checked and
replaced if necessary. 3. 24-volt vehicles: 0-32 volts

1-12. ELECTRICAL FUNDAMENTALS

1-13. TERMS AND DEFINITIONS. The following are electrical terms and
definitions used in this manual:

PAGE 2
 0V

NOTE
The use of digital voltmeters is highly recommended for the following reasons:
• Digital voltmeters are generally more accurate than analog (needle movement) 7.5 V
instruments.
• Digital readings need no interpretation; everyone sees the same number.
8.5 V 0V
• Digital instruments are generally auto ranging; they automatically select the proper
range for the value of the reading.
• Reversing polarity with a digital instrument will simply result in12.5 V
a negative reading
V1 0.3 V
(minus sign) whereas with an analog voltmeter, reversing polarity could damage the 7.2 V

meter. V2
12.5 V are not0V
• If analog meters - read directly facing the meter, inaccuracies may result. 8.5 V

1-16. VOLTMETER USE. Figures 1-6 through 1-8 7.5 V

0 V illustrate the proper use
of the voltmeter
V1 and the types of readings that can be expected.
V1
12.5 V
1. Figure 1-1 shows the voltmeter being used with noV2
current flow 1.0 V
0 V
or with the starter
12.5V not operating.
8.5 V
12.5 V
V2
V3 0.3 V
0V 0.3 V
0V
- DP-1007
12.5V
V4 FIGURE 1-2. Voltmeter Readings with
OV
Current Flow
0V

NOTE
When the voltmeter is connected parallel to a cable (meter leads and cable ends start and
end at the same point), the meter will measure the voltage potential at both ends of the
7.5 V cable. Without current flowing, the values always will be the same and the voltmeter will
read zero.

8.5 V 0V 2. Figure 1-2 shows the voltmeter being used with current flow
(starter pulling 500 amps).

V1 0.3 V
7.2 V NOTE
The V1 reading (See Figure 1-2) means that with 500 amps flowing through the positive
V2
cable, there is a 1.0 volt drop in that cable. There must be current flow in order to produce
8.5 V DP-1006
a voltage drop. The V2 reading (See Figure 1-2) of 0.3 volt means that with 500 amps
flowing through the negative cable, there is a 0.3 volt drop in the negative cable.
FIGURE 1-1. Voltmeter Readings with
7.5 V

No CurrentV1Flow 3. Figure 1-3 illustrates the digital voltmeter reading in a DC system

1.0 V with both correct and incorrect polarity. Whenever the minus
0 V
sign is displayed, the meter leads must be reversed to obtain the
8.5 V correct polarity.
V2

0.3 V

0.3 V

DELCOREMY.COM PAGE 3
 V1 V1 10A
10A
10 AMPS OR LESS LOAD

12.5 -12.5
DIGITAL VOLTMETER DIGITAL VOLTMETER
CONNECTED CORRECTLY CONNECTED
IN RELATIONSHIP TO INCORRECTLY IN
POLARITY RELATIONSHIP TO
POLARITY (VALUE
CORRECT BUT MINUS
SIGN WILL SHOW TO
ALERT OPERATOR THAT
LEADS ARE REVERSED)
DP-1008
V1 V1
V1 V1
FIGURE 1-3. Correct and Incorrect 10 AMPS OR LESS LOAD
10 AMPS OR LESS LOAD
DP-1009
12.5 Polarity Readings
-12.5
12.5
DIGITAL VOLTMETER
-12.5
DIGITAL VOLTMETER FIGURE 1-4. In-Line Digital Ammeter
DIGITAL
CONNECTED VOLTMETER
CORRECTLY DIGITAL VOLTMETER
CONNECTED
1-17. MEASURING CURRENT FLOW WITH THE AMMETER. The ammeter
CONNECTED
INCORRECTLY IN
is used to
IN CONNECTED
RELATIONSHIP CORRECTLY
TO
measure current flow. The
IN RELATIONSHIP
POLARITY INCORRECTLY
RELATIONSHIP
TO unit of measure TOIN or amp.
is the ampere 2. Figure 1-5 shows an in-line digital ammeter used to measure an
POLARITY RELATIONSHIP
POLARITY (VALUETO UNKNOWN
Unless the induction pickup (clamp-on) ammeter
POLARITY
CORRECT BUT is used, the circuit
(VALUE
MINUS
unknown current draw. An example of this might be the result of
CURRENT
must be opened and the ammeter connected CORRECT
SIGN BUT MINUS
WILLinSHOW
series TO
in order to DRAW
a parasitic load. On the 10 amp scale, the current would be too
SIGNOPERATOR
ALERT WILL SHOWTHAT TO
take measurements. ALERT OPERATOR
LEADS ARE REVERSED) THAT low to be measurable. However, with the meter on the 300 mA
LEADS ARE REVERSED) scale, the current draw in milliamps can be read.
1-18. AMMETER SELECTION. With but a few exceptions (See Figure 1-10),
it is desirable to make ammeter readings without opening up the
circuit and thus disturbing a circuit defect and preventing it from
being discovered. Therefore, the use of a clamp-on induction-type
ammeter is recommended for most of the measurements described
in this manual. This type is easy to use, cannot be damaged by
UNKNOWN
misconnection, and will not damage the vehicle wiring. A clamp-on UNKNOWN
CURRENT
ammeter operates by measuring the magnetic flux produced by CURRENT
DRAW
DRAW
current flow through a conductor and translating that into amperes,
which are displayed on the meter readout.

1-19. AMMETER USE. Figures 1-4 through 1-6 illustrate the use of various
types of ammeters.

1. Figure 1-4 illustrates the use of an in-line digital ammeter. Note

that the circuit must be disconnected in order to use this type
of meter. The type of unit shown is an internal shunt and
generally used for loads of 10 amps or less. Care must be taken
DP-1010
to not measure current greater than the meter rating. This type
of ammeter is not recommended for most of the measurements FIGURE 1-5. In-Line Ammeter
described in this manual. However, if this is the only type
available, be sure to follow the meter manufacturer’s instructions 3. Figure 1-6 shows a clamp-on ammeter, the most common type of
for connection and use. current measurement described in this manual. Zero out the
meter before using and make sure the jaws are completely closed
during use. Place the meter jaws around the cable, with the arrow
points in the direction of current flow, to measure all the current.

PAGE 4
 OHMMETER

OPEN

OHMMETER
CLAMP-ON
TYPE AMMETER
OPEN
OHMMETER

CLAMP-ON
TYPE AMMETER OPEN

CLAMP-ON
TYPE AMMETER
DP-1011

FIGURE 1-6. Clamp-On Type Ammeter

DP-1012
1-20. MEASURING RESISTANCE WITH THE OHMMETER. The ohmmeter is used to
measure electrical resistance. The unit of measure is the ohm. The FIGURE 1-7. Analog Ohmmeter Showing Open
ohmmeter is connected across the unit or portion of the circuit for
Circuit
which the resistance is to be measured. The ohmmeter has its own
power source, usually a small battery, which causes current to flow
through the circuit to be measured. Since the meter power source NOTE
(battery) voltage is known, the current is inversely proportional to Most digital meters have a diode scale ( ) which must be used to check diodes or
the resistance of the circuit. transistors rather than the ohm scale.
The meter automatically computes and reads out the resistance:
1-24. APPLYING AN ELECTRICAL LOAD WITH A CARBON PILE. (See Figure 1-10)
E (voltage) divided by I (current) equals R (resistance).
The carbon pile is a variable resistor designed to carry high current.
1-21. OHMMETER SELECTION. As with voltmeters and ammeters, both analog A carbon pile, along with a voltmeter and ammeter, is normally an
(needle) and digital ohmmeters are available. Digital ohmmeters are integral part of a modern battery tester. In addition to load testing
preferred for the same reasons as the others. Additionally, most batteries, carbon piles are used to test starter and alternator
TRUCK
circuits. FRAME
digital ohmmeters have a diode scale which can be used to test
diodes and transistors.

1-22. OHMMETER USE. Figures 1-7 through 1-9 illustrate some typical uses TOUCHING
TRUCK
FRAME
of the ohmmeter. OHMMETER GROUND

CAUTION TRUCK
FRAME
Typical heavy duty electrical system voltage (12 or 24-volts) could produce a current flow TOUCHING
OHMMETER GROUND
through the ohmmeter that could damage the meter. Never connect an ohmmeter to a
circuit that is under voltage. Always disconnect the battery ground cable before using
the ohmmeter. TOUCHING
OHMMETER GROUND
1-23. As shown in Figures 1-7 and 1-8, the ohmmeter also is useful
as a continuity meter. An infinite ohmmeter reading (See Figure 1-7)
indicates an open circuit (no continuity). A very low (approaching
zero) reading (See Figure 1-8) indicates continuity. Figure 1-9
illustrates some digital ohmmeter applications.

DP-1013

FIGURE 1-8. Analog Ohmmeter Showing

Continuity

DELCOREMY.COM PAGE 5
 EXAMPLES
EXAMPLES

2.3 2.3 .450.450

COIL DIODE
COIL DIODE

0.000.00 OL OL

DP-1015

DIGITAL DIGITAL
DIGITAL DIGITAL
FIGURE 1-10. Carbon Pile
1-27. How well the electrical system components are matched will
determine in a large part how effectively and efficiently the system
will operate. Another important factor in system design is that
system wiring must be adequate to carry the current required by
DP-1014
each circuit.

FIGURE 1-9. Digital Ohmmeter 1-28. HEAVY DUTY SYSTEM BATTERIES. The battery, or batteries, in the heavy
duty electrical system are devices for storing energy. They convert
chemical energy into the electrical energy needed to operate the
CAUTION starter. With the engine running, the alternator supplies electrical
On 24-volt systems, use only a carbon pile specifically designed for 24-volt use. A 12-volt energy to the batteries, which they convert into chemical energy and
carbon pile could be damaged if used in a 24-volt circuit. store for later use.

1-25. THE BASIC HEAVY-DUTY ELECTRICAL SYSTEM. Today’s basic heavy duty
electrical system (See Figure 1-1) consists of batteries (usually
three or four, but up to eight connected), a starter, an alternator, a
magnetic switch, an ignition switch, a push-button switch, and the
required wiring. The batteries provide the high current required by
the starter. The magnetic switch controls the battery current to the
starter solenoid. The ignition and push-button switches activate the
magnetic switch, which in turn energizes the starter. If all functions
work properly, the engine will crank.

1-26. The mechanical energy of the running engine provides the

power for the alternator. The alternator creates the electrical energy
needed to recharge the batteries and power the vehicle’s electrical
accessories and loads.

PAGE 6
 There are three types of lead acid batteries used in commercial
vehicle applications today: the maintenance-free flooded electrolyte
battery, the AGM battery, and the Thin Plate Pure Lead (TPPL)
AGM battery. Unlike maintenance-free, flooded, lead acid batteries
that have liquid electrolyte, an AGM battery contains a glass mat
separator made of fiberglass that is placed between each plate to
absorb the electrolyte.

Fleets should prevent batteries from becoming deeply discharged—

dropping to less than 10 volts due to extended storage with vehicle
support loads. Also, trying to start trucks with a low state of charge
or weak capacity batteries can cause high amperages and low
voltages. This can overheat the starter motor and damage battery
cables.

A voltmeter on the battery terminals will indicate the battery’s State

of Charge (SOC).

AGM
State of Charge Flooded Battery TPPL AGM Battery
Battery

100% 12.70+ 12.80+ 12.84+

75% 12.40 12.60 12.50

50% 12.20 12.30 12.20

25% 12.00 12.00 11.90

0% 11.80 11.80 11.50

DELCOREMY.COM PAGE 7
 SECTION II

DIAGNOSIS FLOW CHARTS

PRELIMINARY DIAGNOSIS FLOW CHART
2-1. OVERCHARGE SYMPTOMS
• High voltmeter readings
• Battery smells bad
• Battery spews acid or smells
• Bright or burned out lights

VERIFY COMPLAINT

RUN ENGINE APPROX 2000 RPM

CHECK VOLTS AT ALTERNATOR
LESS
THAN 15.5 V
MORE
THAN 15.5 V

EXTERNAL REGULATOR
INTERNAL VOLTMETER
DEFECTIVE CHECK DASH
USE REG. SVC. BULLETIN VOLTMETER
REPLACE ALTERNATOR TO ISOLATE DEFECT

OK
REPAIR VOLTMETER

120˚F OR MORE CHECK BATTERY

TEMPERATURE

119˚F OR
RETEST WITH COOL, LESS
CHARGED BATTERIES

DEFECTIVE TEST BATTERIES

(PAGE 3-1)

REPLACE DEFECTIVE
BATTERY OK

COMPLETE

COMPLETE

PAGE 8
 PRELIMINARY DIAGNOSIS FLOW CHART
2-2. UNDERCHARGE SYMPTOMS
• Slow or no cranking
• Low voltmeter reading
• Dim lights/slow turn signal flashers

VERIFY COMPLAINT

LOOSE
MISSING
CHECK DRIVE BELT
OK

TIGHTEN BELT TO
MANUFACTURER
TENSION SPECS LOCKED OK
TEST BATTERIES CHECK PULLEYS FOR
(PAGE 11) LOCKED BEARINGS

OK
START VEHICLE

CHECK ALTERNATOR REPLACE BELT

VOLTAGE & OUTPUT OK BUT REPAIR DEFECTIVE
(PAGE 19) DISCHARGED COMPONENT
CHARGE BATTERIES

OK

OK CHECK CRANKING SLOW

CIRCUIT CRANK ENGINE
(PAGE 12)

DEFECTIVE OK

CHECK STARTER REPAIR AND VERIFY CHECK ALTERNATOR

SOLENOID CIRCUIT REPAIR VOLTAGE & OUTPUT
(PAGE 14) (PAGE 19)

DEFECTIVE OK

SEE STARTER
REPLACEMENT
DETERMINATION
(PAGE 17)

REPAIR WIRING
CIRCUIT - VERIFY
REPAIR

DELCOREMY.COM PAGE 9
 PRELIMINARY DIAGNOSIS FLOW CHART
2-3. MILLED PINION SYMPTOMS
• Starter spins / no-crank
• Click / no-crank (may be intermittent)

VERIFY COMPLAINT

CONNECT VOLTMETER
MORE THAN 6.0 V FROM SOLENOID “S” NO VOLTS
TERMINAL TO GROUND –
ENGAGE START SWITCH

SYMPTOMS CONTINUE
REMOVE STARTER – MILLED PINION CHECK AND REPAIR
VISUALLY CHECK PINION SOLENOID CIRCUIT

OK OK

REPAIR OR REPLACE
STARTER REPAIR VERIFIED
(DO NOT INSTALL)

MILLED TEETH
VISUALLY CHECK
RING GEAR

OK

REPLACE RING GEAR

AND CHECK FLANGE
TO FLYWHEEL DIM

CHECK STARTER PER

APPROPRIATE DEFECTIVE
SERVICE BULLETIN

OK

REINSTALL STARTER AND REPLACE STARTER

PERFORM CIRCUIT CHECKS AND VERIFY REPAIR
(SEE PAGE 3-4)

PAGE 10
 SECTION III

DIAGNOSTIC TESTING
Temp. 0F 70 50 30 15 0

3-1. TESTING FLOODED LEAD ACID MAINTENANCE FREE Min. Volts 9.6 9.4 9.1 8.8 8.5

BATTERIES WITH A HYDROMETER EYE

CAUTION e. If recorded voltage does not meet or exceed that in table,
When handling batteries, wear face or eye protection and provide good ventilation. Have a replace battery. Otherwise, battery is okay.
water supply available, and keep away from fire, flame or sparks.
3-3. TEST COMPLETION.
3-2. TEST PROCEDURE.
Clean
Disconnect 1. Cable ends and battery terminals with wire brush.

Tighten
NOTE
1. Battery hold-downs to specifications.
If battery has threaded terminals, use terminal adapters or verify you are testing on the
lead pads not the threaded terminals. Testing using the studs can create a false bad battery
NOTE
reading.
Leave battery cables disconnected and proceed with wiring tests.

NOTE
If you are using an hand held electronic tester, then follow the instructions provide with the PRIMARY BATTERY ST1201 ADAPTER
tester. CONNECTION AREA

Inspect
1. Each battery visually for damage.

2. Battery hydrometer eye.

STUD TERMINAL
• If battery has no hydrometer eye, proceed to step 3.
• Eye shows green, proceed to step 3.
• Eye shows dark, recharge battery, then proceed to step 3.
• Eye shows yellow, replace battery.

3. Apply 300 amp load to battery for 15 seconds and turn off load.
Wait one minute.

Test

4. If battery has no hydrometer eye, measure terminal voltage:

DP-1019
a. If 12.4 volts or more, continue test.

b. If less than 12.4 volts, recharge battery, and repeat steps

3 and 4. FIGURE 3-1. Testing Batteries
Test

5. All batteries passing previous inspection or test as follows: 3-4. TESTING BATTERIES
a. Apply test load of 1\2 CCA rating at 0˚F in amps. CAUTION
When handling batteries, wear face or eye protection and provide good ventilation. Have a
b. After 15 seconds with load on, measure and record battery water supply available, and keep away from fire, flame or sparks.
terminal voltage.

c. Turn load off.

d. Estimate battery temperature and check recorded voltage

against following table.

DELCOREMY.COM PAGE 11
3-5. TEST PROCEDURE Temp. 0F 70 60 50 40 30 20 10 0
Min. Volts 9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5
Disconnect

NOTE f. If recorded voltage does not meet or exceed that in table,

If battery has threaded terminals, use terminal adapters or verify you are testing on the replace battery. Otherwise, battery is okay.
lead pads not the threaded terminals. Testing using the studs can create a false bad battery
reading. 3-6. TEST COMPLETION.

NOTE Clean
If you are using an hand held electronic tester, then follow the instructions provide with the
1. Cable ends and battery terminals with wire brush.
tester.
Tighten
Inspect
1. Battery hold-downs to specifications.
1. Each battery visually for damage.
NOTE
2. Electrolyte level.
Leave battery cables disconnected and proceed with wiring tests.
• If fluid is above top of plates in all cells, proceed to step 3.
• If fluid is not above top of all plates, add water as required
and charge battery for 15 minutes at 15-25 amps to mix
electrolyte. Then proceed to step 3.

3. Electrolyte specific gravity with hydrometer at 80˚ F. Readings

for all cells should not be less than 1.230. The difference
between high and low reading should not exceed 0.050.
• If battery meets above requirements, proceed to next test.
• If readings show a difference of more than 0.050, replace the
battery.
• If readings show less than 0.050 difference but one or more
cells read less than 1.230, recharge the battery.

Remove

1. All battery caps.

Test
DP-1020
2. Apply 300 amp load to battery for 15 seconds and turn off load.

3. If blue haze is seen in any cell, replace battery. Otherwise,

proceed with next test.
FIGURE 3-2. Testing Batteries
Test
3-7. BATTERY CABLE TEST WITH SINGLE BATTERY
1. All batteries passing previous inspections or tests as follows: LOCATION (SEE FIGURE 3-3)
a. Measure and record electrolyte temperature and replace
vent caps. CAUTION
If the vehicle has a combination 12/24-volt system using a series-parallel switch or a T/R
b. Apply test load of 1\2 CCA rating at 0˚F in amps. alternator, do not use this procedure. Contact Technical Support at 800-372-0222 or email
delcoremytechsupport@phinia.com for information on such systems.
c. After 15 seconds with load on, measure and record battery
terminal voltage.

d. Turn load off.

e. Check recorded voltage against following table for

electrolyte temperature.

PAGE 12
 Slow or sluggish cranking may be caused by high resistance in the 3. Add positive cable loss (V4) and negative cable loss (V5) to get
battery cables or connections, especially in cold weather. After all total cable loss (V3). This loss (V3) shall not exceed:
batteries test well and the terminals are clean, check the battery
cables. This involves placing an adjustable carbon pile load on the • 12-volt system with 37MT, 40MT, 41MT or 42MT starter —
batteries at the starter and then measuring the voltage drop in each 0.500 volt maximum voltage loss
cable. The voltage drop in the positive cable plus the voltage drop in • 12-volt system with 50MT starter — 0.400 volt maximum loss
the negative cable equals the total drop or the difference between • 24-volt system with 37MT, 40MT, 41MT, 42 MT, or 50 MT
the battery voltage and the starter voltage. starter — 1.000 volt

3-8. TEST PROCEDURE. 4. Replace cables or repair circuits with excessive voltage drop.

3-9. TEST COMPLETION. If temporary 12-volt test connections were made

NOTE
for 24-volt systems, reconnect batteries to vehicle specifications
For a 24-volt system, use a 24-volt carbon pile. As an alternative, connect only one
for 24-volt operation before starting vehicle. However, if the tests
12-volt battery to the system (disconnect all other batteries). Test at 12-volts but use
following are to be performed, keep the temporary 12-volt hook-up.
the amperage specified for a 24-volt system. Immediately upon completion of tests,
reconnect batteries in the approved manner for a 24-volt system.

Connect

CAUTION
Starter solenoid BAT terminal is at battery voltage when batteries are connected.

1. Positive carbon pile lead to starter solenoid BAT terminal.

2. Negative carbon pile lead to starter ground terminal.

3. Battery cables (see NOTICE above) if not already connected.

NOTE
At starter, make voltmeter connection to terminal—not to carbon pile clamp.

4. Low scale digital voltmeter from starter solenoid BAT terminal to

battery positive.

Test

1. Turn on carbon pile and adjust load to 500 amps (250 amps for
24-volt system).

2. Read and record positive cable voltage drop (V4), then turn off
carbon pile.

Connect

NOTE FIGURE 3-3. Battery Cable Test –

At starter, make voltmeter connection to terminal—not to carbon pile clamp.
Typical 12-Volt System
1. Low scale digital voltmeter from starter ground terminal to
battery negative.

Test

1. Turn on carbon pile and adjust load to 500 amps (250 amps for
24-volt system).

2. Read and record negative cable voltage drop, (V5) then turn off
carbon pile.

DELCOREMY.COM PAGE 13
3-10. BATTERY CABLE TEST WITH DUAL-BATTERY FIRST SET
LOCATIONS (SEE FIGURE 3-4)
This test applies if the vehicle has more than one battery location
and the batteries are connected to the starter by separate cables.
Essentially, this is the same as the previous test with a single battery
location (paragraphs 3-7 through 3-9) except as follows:

3-11. TEST PROCEDURE (See Figure 3-4).

SECOND SET
NOTE
If the system usually operates on 24-volts, connect one battery at each location to the
starting motor, making a temporary 12-volt system.

1. Disconnect batteries from first set.

NEGATIVE
2. Test second set cables as described in paragraph 3-8 except VOLTAGE
LOSS
apply 250 amp load at starter (125 amp for 24-volt system).
POSITIVE
VOLTAGE
3. Use same voltage drop or loss limits as specified in LOSS
paragraph 3-8.

4. Reconnect first set of batteries and disconnect second set.

5. Repeat steps 2 and 3 for first set of cables.

6. Replace cables or repair circuits with excessive voltage drop.

3-12. TEST COMPLETION. If temporary 12-volt test connections were made

for 24-volt system, reconnect batteries to vehicle specifications
for 24-volt operation before starting vehicle. However, if the tests
following are to be performed, keep the temporary 12-volt hook-up.

CARBON PILE

FIGURE 3-4. Battery Cable Test -

Typical Dual Box 12-Volt System

3-13. STARTER SOLENOID CIRCUIT TEST

The starter shifting in and out, or not pulling in, is often caused by
high resistance in the starter solenoid circuit. When the solenoid
circuit has excessive voltage loss, the starter pinion may not
engage the flywheel. If it does engage, it may drop out too soon
when battery voltage lowers. The solenoid circuit usually consists
of a magnetic switch with leads to and from the starter solenoid.
Some vehicles use only a push-button switch to control the starter
solenoid and this same test applies.

PAGE 14
 NOTE
For starters with an integral magnetic switch, use the test procedures specific to those
starters.

NOTE
When testing 24-volt systems, use the same temporary 12-volt connection as for the
Battery Cable Test, paragraph 3-7.

3-14. SOLENOID CIRCUIT VOLTAGE LOSS TEST (See Figure 3-5).

VOLTAGE (6)
Disconnect

1. Lead to S terminal on starter solenoid.

Connect

1. Carbon pile to switch wire lead and to starter ground terminal (a

small clamp or jumper wire may be helpful).

2. Positive lead of digital voltmeter set on low scale to solenoid BAT

terminal.

3. Negative lead of voltmeter to switch wire lead to which carbon

pile is connected. Meter will show battery voltage. CARBON PILE
DP-1023
NOTE
In the following step, if the magnetic switch does not close on a 12-volt vehicle, perform
Magnetic Switch Circuit Test, paragraph 3-18, then return to this point in the Starter FIGURE 3-5. Starter Solenoid
Solenoid Circuit Test. Circuit Test
NOTE 3-15. WIRING TEST (See Figure 3-6). With carbon pile connected as
In the following step on a 24-volt vehicle, if the temporary 12-volt system will not close instructed in previous Starter Solenoid Circuit Test, proceed as
the magnetic switch, bypass it with a heavy jumper connected between the two large follows:
studs on the magnetic switch. Electrically this does the same thing as pushing the button
and closing the switch. With no button to release, the jumper must be disconnected after Connect
each voltage reading.
1. Plus lead of digital voltmeter set on low scale to solenoid BAT
Test terminal.

1. Have assistant push starter button with key on. Listen for sound 2. Minus lead of voltmeter to a large terminal on magnetic switch.
of magnetic switch closing. Voltmeter reading should be zero. If voltage shows, reconnect lead to other large terminal on
magnetic switch.
2. Turn on and adjust carbon pile to 100 amp load (60 amp if 24-
volt system). NOTE
In the following step, on a 24-volt vehicle, if the temporary 12-volt system will not close
3. Read and record voltage (V6) onvoltmeter.
the magnetic switch, bypass it with a heavy jumper connected between the two large
4. Voltage loss shall not exceed: studs on the magnetic switch. Electrically this does the same thing as pushing the button
12-volt system - 1.0 volt and closing the switch. With no button to release, the jumper must be disconnected after
24-volt system - 2.0 volt each voltage reading.

5. If circuit voltage loss is less than maximum, solenoid circuit is

okay, turn off and disconnect carbon pile and proceed to
Magnetic Switch Circuit Test, paragraph 3-18. If voltage loss
exceeds maximum, loss is excessive. This may be caused by loose
terminals, corrosion, too small a wire, switch located too far from
starter, or worn out magnetic switch. Perform Wiring Test,
paragraph 3-15, and Magnetic Switch Contactor Test, paragraph
3-16, to isolate the problem.

DELCOREMY.COM PAGE 15
 Test

1. Push starter button with key on.

2. Turn on and adjust carbon pile to 100 amp load (60 amp if
24-volt system).

3. Read and record voltage (V9) onvoltmeter.

Connect

1. Positive lead of digital voltmeter set on low scale to switch wire FIRST
WIRE CONTACTOR
lead to which carbon pile is connected. LOSS (9) LOSS (11)

2. Negative lead of voltmeter to other large terminal on magnetic

switch. SECOND WIRE LOSS (10)

Test

1. Push starter button with key on.

2. Turn on and adjust carbon pile to 100 amp load (60 amp if CARBON PILE
24-volt system).

3. Read and record voltage (V10) on voltmeter.

4. Add voltage loss (V10) to voltage loss (V9), previously recorded,

to get total wire voltage loss.
DP-1024
5. Total wire voltage loss shall not exceed:
12-volt system - 0.8 volt
24-volt system - 1.8 volt FIGURE 3-6. Solenoid Circuit Wiring
6. Replace and repair wiring and connections if voltage loss is and Contactor Test
excessive.
3-17. TEST COMPLETION. Turn carbon pile off. Remove carbon pile and
NOTE voltmeter from circuit. Leave solenoid S wire disconnected and
Perform the following test only if the magnetic switch closed in preceding tests. temporarily taped for insulation at the terminal.

3-16. MAGNETIC SWITCH CONTACTOR TEST (See Figure 3-6). With carbon pile
3-18. MAGNETIC SWITCH CIRCUIT TEST
connected as instructed in previous Starter Solenoid Circuit Test,
proceed as follows: This test must be performed using full voltage of the system. If a
24-volt system was temporarily connected to a 12-volt system for
Connect a previous test, proceed to the Alternator Wiring Test, paragraph
3-26. Then, return to this test after the batteries have been
1. Digital voltmeter set on low scale across large terminals of reconnected to the 24-volt system. Note that the lead to the S
magnetic switch. Battery voltage will show immediately. terminal on the starter solenoid remains disconnected from previous
tests (See Figure 3-7).
Test

1. Push starter button with key on. Voltage will read zero.

2. Turn on and adjust carbon pile to 100 amp load (60 amp if
24-volt system).

3. Read and record voltage (V11) across magnetic switch on

voltmeter, then release starter button.

4. Magnetic switch contactor voltage loss (V11) shall not exceed

0.2 volts for 12- or 24-volt system.

5. Replace magnetic switch if contactor voltage loss is excessive.

PAGE 16
 3-19. TEST PROCEDURE.

NOTE
Magnetic switch that does not close or drops out too soon can be caused by high
resistance or open circuit in the control circuit. PUSH IGNITION
BUTTON
NOTE MAGNETIC
SWITCH
Leave the S lead disconnected to prevent engine from cranking during these tests. VOLTAGE (13)

Connect V(15)

1. Digital voltmeter set on battery voltage scale to two small

V(16)
terminals on magnetic switch. If magnetic switch has only one V(17) V(18)
small terminal, use switch bracket for other connection. V(19)

Test V(14)

1. With key on, push start button. Listen for click that signifies
magnetic switch closing. Note and record voltmeter reading
V(13).
BATTERY
CABLE
2. If magnetic switch closed (click detected or voltage at both large VOLTAGE (12)
switch terminals) and voltage V(13) is within 1.0 volt (2.0 volts for
24-volt system) of battery voltage V(12), this circuit is okay. DP-1025

3. If magnetic switch does not close and voltage V(13) is within 1.0 FIGURE 3-7. Magnetic Switch
volt (2.0 volt for 24-volt system) of battery voltage V(12), replace
magnetic switch and retest.
Circuit Test
4. If voltage V(13) is more than 1.0 volt (2.0 volt for 24-volt system)
below battery voltage, move the voltmeter lead on the magnetic
3-21. STARTER REPLACEMENT DETERMINATION
switch ground to frame or motor ground terminal. With key Up to this point, the batteries and starter wiring have been checked.
on, push start button and read voltage V(14). If voltage V(14) The following additional checks should be made before considering
is within 1.0 volt (2.0 volts for 24-volt system) of battery voltage, starter replacement, and finally, the criteria for starter replacement,
repair magnetic switch ground lead or connections. If not, if necessary.
replace voltmeter ground lead at magnetic switch ground
3-22. COLD WEATHER CRANKING. Starter circuits with a magnetic switch also
terminal.
can fail to hold during cold weather starting and low voltage, even
5. Repeat step 4, moving voltmeter plus lead to the following though the switches and circuits tested okay at higher temperatures.
locations and measuring the specified voltages with the key on This condition will sound as though the starter is failing to stay
and the push-button depressed. engaged with the engine. It is caused by the cold weather low voltage
of the system releasing the electrical connection of the magnetic
If any voltage is not within 1.0 volt (2.0 volts for 24-volt system) of switch. To test for this condition, proceed as follows:
battery voltage, repair or replace the wire or component specified
and retest: Test

V(15)-wire between push-button and magnetic switch

CAUTION
V(16) push-button Large terminal studs on magnetic switch are at battery voltage. Engine should crank when
V(17) wire between push-button and key switch jumper is connected.

V(18) key switch 1. With key switch on, press start button and have assistant clamp
V(19) wire between key switch and solenoid BAT terminal heavy battery jumper cable between two large studs on
magnetic switch. Engine should crank.
3-20. TEST COMPLETION. Remove voltmeter from vehicle. If all tests have
been completed satisfactorily, reconnect lead to S terminal on 2. Immediately remove jumper to stop engine cranking.
starter solenoid so that engine can be started.
3. If engine starts with jumper in place, replace magnetic switch.

4. If vehicle now starts properly, make sure starter mounting bolts

are tight and proceed to Alternator Wiring Test.

DELCOREMY.COM PAGE 17
3-23. AVAILABLE CRANKING VOLTAGE. If batteries, switches and wiring have NOTE
been checked and starter still cranks slowly, check for available 24-volt systems must be connected to a temporary 12-volt configuration as described for
voltage at the starter while cranking. Proceed as follows: Battery Cable Test, paragraph 3-8.
NOTE
Test
Before proceeding with this test, make sure that the batteries have been tested and that
1. Have assistant press push-button with key switch on while the terminal has been cleaned and tightened.
measuring voltage across solenoid BAT terminal and starter CAUTION
ground terminal. Alternator output terminal is at battery voltage. Engine must be off for this test.

2. If voltage is 9.0 volts (18 volts for 24-volt system) or less while Connect
cranking, check battery interconnecting cables as specified in
1. Carbon pile to alternator output terminal and to ground.
next step.

3. Measure voltage across each battery while cranking. Touch NOTE

voltmeter leads to terminals of every battery. If difference Jumper wires may be used to extend voltmeter leads if necessary.
between any two battery readings in same box is more than 0.5
2. Digital voltmeter set on low scale from alternator output
volt, or if any cable or connection feels warm to the touch, check
terminal to positive battery terminal.
or replace interconnecting cable(s) as required.
Test
3-24. RING GEAR AND PINION CHECK. One final check before replacing the
starter is to inspect the pinion and ring gear. 1. Turn on and adjust carbon pile to alternator-rated amperage
output.
Inspect
2. Read voltmeter and record voltage (V24), which is positive circuit
1. Pinion and ring gear visually while assistant bars engine over. Be
voltage loss. Immediately turn off carbon pile.
sure to check entire ring gear.
Connect
2. If pinion is damaged, replace starter. If ring gear is damaged,
replace ring gear and note that there is a likelihood the pinion 1. Digital voltmeter set on low scale from alternator ground to
also may be damaged. negative battery terminal.

3-25. STARTER REPLACEMENT. After making all tests specified, if the vehicle Test
does not crank properly, the problem is with the starter or engine.
Replace the starter and re-check to see if engine cranks properly. If 1. Turn on and adjust carbon pile to alternator rated amperage
not, then look for a mechanical problem with the engine. output.

3-26. ALTERNATOR WIRING TEST 2. Read voltmeter and record voltage (V25), which is negative
circuit voltage loss. Immediately turn off carbon pile.
This procedure is the first step in checking out the charging system:
output of the alternator, batteries and accessory loads with a 3. Add positive circuit loss (V24) and negative circuit loss (V25) to
minimum of voltage loss. Any loss slows the rate of charge to the get total system loss (V23). This loss (V23) shall not exceed:
batteries and could cause the batteries to be partially discharged.
• 12-volt system - 0.500 volt maximum voltage loss
Discharged batteries can result in starter damage. Low output
• 24-volt system - 1.000 volt maximum voltage loss
voltage can cause improper performance of other vehicle electrical
components. 4. Replace cables or repair circuits with excessive voltage loss.

3-27. TEST PROCEDURE (See Figure 3-8). Instead of using the alternator
output, this test uses the same current but draws it from the
batteries. Using a carbon pile load, current flows in reverse through
the circuit with the engine off. Proceed as follows:

PAGE 18
 3-28. TEST COMPLETION. Remove carbon pile and voltmeter. For 12-volt 3-30. ALTERNATOR VOLTAGE OUTPUT TEST. Conduct this test at shop
systems, proceed with Alternator Replacement Determination. For temperature (See Figure 3-9).
24-volt systems, proceed as follows:
Connect
1. Reconnect temporary 12-volt system back to 24-volt system.
1. Digital voltmeter from positive alternator terminal to alternator
2. If Magnetic Switch Circuit Test was delayed, conduct at this time. ground.

3. After completing Magnetic Switch Circuit Test, be sure to Test

reconnect lead to S starter solenoid terminal. Then proceed with
1. Start engine and make sure all vehicle electrical loads are turned
Alternator Replacement Determination.
off. Fast idle engine until voltage stabilizes (does not increase) for
two minutes.

2. Check that alternator output voltage does not exceed 15.5 volts
(31 volts for 24-volt system). Remove voltmeter.
NEGATIVE
CIRCUIT
LOSS
(25)

CARBON
PILE
NEGATIVE
POSITIVE CIRCUIT
CIRCUIT LOSS
LOSS (24) (25)

CARBON
PILE
POSITIVE
CIRCUIT
LOSS (24)

DP-1026

FIGURE 3-8. Alternator Wiring Test -

Typical 12-Volt System
DP-1026

3-29. ALTERNATOR REPLACEMENT DETERMINATION FIGURE 3-8. Alternator Wiring Test -

If the alternator wiring circuits are okay, conduct the following tests Typical 12-Volt System
to determine if the alternator must be replaced.

NOTE 3-31. ALTERNATOR AMPERAGE OUTPUT TEST. Conduct this test at shop
Make sure that alternator mounting hardware is secure and that belts are OK before temperature (See Figure3-10).
testing alternator.
Connect
NOTE 1. Carbon pile across the vehicle batteries hooked in parallel.
Batteries must be satisfactorily load tested and near full charge with more than 12.4 volts
— no load voltage. 2. Induction ammeter clamped around alternator output wire.

DELCOREMY.COM PAGE 19
 NOTE
If more than one wire is connected to the alternator output terminal, clamp around ALL
these wires.

Test

NOTE
In the following test, alternator should be turning at approximate rated speed. Most heavy
duty alternators are rated at 5000 rpm. Check manufacturer’s specifications for specific
alternator being tested.

1. If off, start engine and make sure all vehicle electrical loads are
turned off. Speed up engine. Turn on and adjust carbon pile until
CARBON PILE
ammeter reads its highest value. Record this reading.

2. Turn off carbon pile and engine.

3. If reading is zero (no output), magnetize the rotor with the

alternator hooked up normally. Momentarily connect a jumper
lead from the battery positive (+) to the alternator relay (R)
or indicator (I) terminal. This procedure applies to both negative
and positive ground systems and will restore the normal residual
magnetism.
DP-1028
DP-1028
4. Repeat steps 1 and 2. If output is still zero, replace the alternator.

3-32. ALTERNATOR REPLACEMENT. Replace alternator if either of the

FIGURE 3-10. Amperage Output Test
following conditions exist:

1. Alternator output voltage exceeds 15.5 volts (paragraph 3-30).

If alternator has separate regulator, use the appropriate
regulator service bulletin to isolate the defect.

2. Alternator output current is not within 10% of alternator rated

output (stamped on alternator case). Examples: 30-SI - 105
amps, 26-SI - 85 amps, and 21-SI - 100 amps.

3-33. COMPLETION OF ALL TESTS

Make sure that all test instruments have been removed from the
vehicle and that the vehicle wiring, if altered, has been returned to
the operational state.

PAGE 20
 SECTION IV

SUMMARY
As the diagnostic procedures in this manual become part of your
routine preventative maintenance program, here are two key tips to
remember:

1. Don’t jump to early conclusions.

2. Perform the diagnostic procedures in the exact order listed.

These diagnostic procedures, if followed correctly, will enable you to

diagnose issues and maintain heavy duty electrical systems so that
they will perform well. However, the manual may not cover all the
variables that you may encounter.

If you need assistance, contact Technical Support at 800.372.0222 or email

delcoremytechsupport@phinia.com.

DELCOREMY.COM PAGE 21
 SECTION V

APPENDIX
5-1. Smart IMS or SIMS Diagnostic Steps When troubleshooting a vehicle system equipped with SIMS/IOCP,
voltage and temperature are critical during diagnosis:
The Smart Starter with integrated magnetic switch (IMS) relay and
integrated over crank protection (IOCP) is designed to protect the ENGAGEMENT MONITOR/AUTO RETRY – 12-VOLT SYSTEM:
vehicle system from multiple system-related failures. The Smart The system will attempt to engage the pinion three times in less than
Starter will accomplish this by not allowing the starter system to one second. After three failed attempts, cycle the engine ignition off/
function in detrimental conditions to the starter or electrical system. on before making another crank attempt.
To troubleshoot, you must first verify that the vehicle is equipped
with the Smart Starter SIMS relay and integrated OCP. The SIMS LOW VOLTAGE LOCKOUT – 12-VOLT SYSTEM:
relay is programmed to protect the vehicle from these failure modes: Start attempts are not allowed if open circuit voltage is less than 12
volts (equal to 25% of the battery’s state of charge). Check system
• Starter engagement monitor/auto start retry – click no crank or voltage and charge batteries if this condition is present before
prolong power removing starter.
• Running engine lockout – engagement into running engine
• System low/high voltage lockout – over crank and pinion chatter HIGH VOLTAGE LOCKOUT – 12-VOLT SYSTEM:
• Time limited crank – over crank If starter sees system voltage of greater than 14 volts, the SIMS/
• Auto disengage at engine start – extended overrun IOCP will lock out, preventing the start attempt. This protects
• Integrated OCP thermal cutout switch – heat damage from against high voltage jumpstarts (starter will be locked out if
extended crank attempting jumpstarts above 14 volts).

VISUAL DIFFERENCES INTEGRATED OVER CRANK PROTECTION – 12-VOLT SYSTEM:

If the starter is continuously cranked and reaches an internal
STANDARD IMS RELAY SIMS RELAY
temperature greater than 150˚C, the OCP switch will open and
abort the start attempt. This allows the starter to cool down and the
OCP to close so that the crank cycle can be performed. Allow the
starter to cool before removing from the vehicle.

Note:
When troubleshooting the starting system, verify that there is suitable voltage at the “S”
terminal before removing the starter. The SIMS unit may be protecting the starting system
if voltages are either high or low, or if over-cranking occurs and the OCP switch opens
due to high temperatures.

CAUTION – SMART STARTER!

CAUTION LABEL
SMART IMS WITH IOCP EQUIPPED
(INTEGRATED OVER CRANK) Caution label to
PREVENTS CRANKING UNDER be placed on can of SIMS
LOW/HIGH VOLTAGE AND HIGH unit
TEMPERATURE CONDITIONS

PAGE 22
 Connect to same ground point as standard circuit
(may be through relay or fuel pressure switch)
Thermostat Leads (2)

Motor
Thermostat
Connections

Connect to same ground point as standard circuit

(may be through relay or fuel pressure switch)
Thermostat Leads (2)

DP-1029

Motor
DELCO REMY STARTERS WITH OVERCRANK PROTECTION
Thermostat
Connections
5-2. OVERCRANK PROTECTION (OCP) CIRCUIT CHECK charging current
A is divided and each battery receives only the
charging current it can accept V voltage. (See
V at the charger’s V Fig. 2
To check the thermostat in the OCP circuit for continuity, detach
for typical hook-up.) Because of these differences, the charging
CHARGER
wiring harness connector and connect an ohmmeter to the two
procedures also differ.
thermostat terminals on the starter. The ohmmeter should read
zero. If not, thermostat is open circuit and the starter should be No matter which type of charger is used, differences exist among
A CHARGER AMMETER V TEST VOLTMETER
replaced prior to proceeding with other tests in this booklet. batteries: age, capacity, size, state of charge, and type. These
differences mean that time and attention must be given toDP-1029
batteries
DP-1030
DP-1029
DO NOT check thermostat when hot since it is supposed to be open
during the group-charging process.
circuit above certain temperatures.

5-3. MULTI-BATTERY CHARGING WITH SERIES AND PARALLEL CHARGERS

A
A V
These procedures assist in providing charged batteries for future V V V
service. However, “boost” charging or “fast” charging is not covered. CHARGER
CHARGER
Below are basic guidelines for charging groups of batteries and
supplements information contained in the Delco Service Bulletins,
1B-115 and 1B-116. A CHARGER AMMETER
A CHARGER AMMETER V TEST VOLTMETER
V TEST VOLTMETER
DP-1030
DP-1031
DP-1030
DP-1030
The two types of battery chargers in use today for charging a group
of batteries are:
FIGURE 1.
• Current-limiting (often called Constant – Current or Series
A
Chargers) V
• Voltage-limiting (often called Constant – Voltage or Parallel
CHARGER
Chargers)

With current-limiting, the batteries are connected so that each

A CHARGER AMMETER V TEST VOLTMETER
battery receives the same amount of charging current. (See Fig. 1 for
DP-1031
DP-1031
typical hook-up.)
FIGURE 2.
With voltage-limiting, the batteries are connected so that the

DELCOREMY.COM PAGE 23
To prevent undercharging or overcharging and battery damage on 5-5. GROUP CHARGING ON VOLTAGE-LIMITING OR PARALLEL CHARGERS
the charging rack, the following procedures are recommended:
1. Visually inspect all batteries for cracked covers or cases; replace
NOTE obviously damaged batteries.
The following recommendations are for batteries with electrolyte and plates at room
a. Filler-cap batteries: Check with hydrometer; if reading
temperatures of 55˚ to 85˚F (13˚ to 30˚C). Extremely cold batteries accept very little
is 1.230 or more, test as outlined in Delco Service Bulletin
charging current and will not conform to the suggested procedures.
1B-115. If reading is below 1.230, proceed with charging
5-4. GROUP CHARGING ON CURRENT-LIMITING OR SERIES CHARGERS procedure. If fluid level is low, add water to bring level
sufficiently high for hydrometer readings, but not to split ring,
1. Visually inspect all batteries for cracked covers or cases; replace then proceed with charging. After charging, add water to split
obviously damaged batteries. ring.

a. Filler-cap batteries: Check with hydrometer. If reading b. Freedom batteries: Check built-in hydrometer; if clear or
is 1.230 or more, test as outlined in Delco Service Bulletin yellow, replace battery. If hydrometer has a green dot, do
1B-115. If reading is below 1.230, proceed with charging not charge, but test as outlined in Service Bulletin 1B-116. If
procedure. If fluid level is low, add water to bring level hydrometer is dark, proceed with charging procedure.
sufficiently high for hydrometer readings, (but not to the split
ring), then proceed with charging. After charging, add water just 2. Connect batteries and test voltmeter to charger as shown in
to split ring. Figure 2. Make sure that all connections are clean and tight.
Set charging voltage setting to a setting that does not exceed
b. Freedom batteries: Check built-in hydrometer; if clear or 16.0 volts. The charger may not be able to reach this voltage
yellow, replace the battery. If hydrometer has a green dot, do initially, but as batteries become charged and accept less current,
not charge, but test as outlined in Delco Service Bulletin 1B- the voltage will rise. The ammeter of the charger is indicating the
116. If hydrometer is dark, proceed with charging procedure. total current flow to the connected batteries. This current divides
into the various batteries. It is not a measure of each battery’s
2. Connect batteries to charger as shown in Figure 1. Do not
current acceptance. Do not exceed the charger’s capabilities by
exceed the charger’s voltage capabilities by connecting too many
connecting too many batteries. Follow the charger manufacturer’s
batteries. Make sure all connections are clean and tight. Set
directions.
charging rate within 5-10 ampere range and maintain this
charging rate throughout the charging procedure. 3. After two or three hours, check batteries at hourly intervals as
follows:
3. After two or three hours of charging, check batteries as follows:
a. Filler-cap batteries: Take hydrometer readings at hourly
a. Filler-cap batteries: Take hydrometer readings at hourly
intervals. Correct readings to 80˚F (27˚C). Remove any
intervals. Correct readings to 80˚F (27˚C). Remove any battery
battery from the charge when there is no increase in specific
from charge when there is no increase in specific gravity after
gravity after three successive hourly readings. Any battery
three successive hourly readings. Any battery that becomes
that becomes hot (125˚F, 52˚C) or violently gasses should be
hot (125˚F, 52˚C) or violently gasses, should be removed from
removed from the charger and tested. In the event that a hot
the charger for testing. Readjust control to maintain the same
battery is removed, most of the charging current was going to
charging rate after the batteries are removed.
that battery and it will be necessary to continue charging the
b. Freedom batteries: Check for green dot indication. Shake remaining batteries since they received very little charging
or tilt batteries at hourly intervals to see if green dot will stay current.
visible. Also check terminal voltage of each battery with test
b. Freedom batteries: Check for green dot indication. Remove
voltmeter connected, as shown in Figure 1. While on charge, if
from charger when green dot stays visible. Any battery that
voltage across the battery is 16.0 volts or more, or if the green
becomes hot (125˚F, 52˚c), as determined by touching and
dot appears, remove battery from charger. Any battery that
feeling the case, or violently gasses, should be removed from
becomes hot (125˚F, 52˚C), as determined by touching and
the charger and tested. In the event that a hot battery is
feeling the case, or any battery that violently gasses, should
removed, most of the charging current was going to that battery
be removed from the charger for testing. Readjust control
and it will be necessary to continue charging the remaining
to maintain the same charging rate on remaining batteries as
batteries, since they received very little charging current.
charged batteries are removed.
Readjust control to keep voltage below 16.0 volts, if necessary,
4. After charging, all batteries should be tested as described in the as batteries are removed.
testing procedure in Delco Service Bulletins 1B-115 and 1B-116
4. After charging, all batteries should be tested as described in the
to make sure batteries are usable.
testing procedure in Delco Service Bulletins 1B-115 and 1B-116
to make sure batteries are usable.

PAGE 24
 5-6. HEAVY DUTY DIAGNOSTIC PROCEDURES DATA
Section 3-7 BATTERY CABLE TEST
W/500 AMP LOAD (FROM FIGURE 3-3)

POSITIVE CABLE NEGATIVE CABLE NEGATIVE CABLE

LOSS LOSS LOSS
+ +
V4 V5
_______________________________ _______________________________ _______________________________
(MAX. 0.500 V)

Section 3-15 and 3-16 STARTER SOLENOID CIRCUIT TEST

W/100 AMP LOAD (FROM FIGURE 3-6)

FIRST WIRE SECOND WIRE MAG SWITCH TOTAL SOLENOID

LOSS LOSS LOSS CIRCUIT LOSS
+ + =
V4 V10 V11
______________________ ______________________ ______________________ ______________________
(MAX. 1.00 V)

Section 3-27 ALTERNATOR WIRING LOSS

AMP LOAD = ALTERNATOR RATED OUTPUT (FROM FIGURE 3-8)
POSITIVE CIRCUIT NEGATIVE CIRCUIT ALTERNATOR CIRCUIT
LOSS LOSS LOSS
+ +
V24 V25
_______________________________ _______________________________ _______________________________
(MAX. 0.500 V)

(AMP LOAD AND MAXIMUM VOLTAGE LOSSES SHOWN ARE FOR 12-VOLT SYSTEMS.)

DELCOREMY.COM PAGE 25
 NOTES
_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

PAGE 26
 NOTES
_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

DELCOREMY.COM PAGE 27
 NOTES
_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

PAGE 28
 NOTES
_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________

DELCOREMY.COM PAGE 29
 M13101 03/24 DELCOREMY.COM

For Customer Support, call:

1.800.372.0222

DELCO REMY is aDELCO REMY istrademark

registered a registeredof
trademark
GeneralofMotors
GeneralLLC,
Motors LLC, licensed
licensed to PHINIA
to PHINIA TechnologiesInc.
Technologies Inc.