Table of Contents
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Table of Contents
Summary of Contents for Borg Warner Delco Remy 28MT
- Page 1 Diagnostic Procedures Manual For Starters and Alternators...
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Page 2: Table Of Contents
Table of Contents Section Page Introduction and Description 1–1. Introduction 1–7. Description 1–12. Electrical Fundamentals II ) Diagnosis Charts 2–1. Overcharge Symptoms 2–2. Undercharge Symptoms 2–3. Milled Pinion Symptoms III ) Testing 3–1. Testing Freedom Batteries 3–4. Testing Conventional Batteries 3–5. -
Page 3: Introduction And Description
These procedures are applicable to systems using heavy duty starters 1. A variable carbon pile load tester with more than 500 amps such as: Delco Remy 28MT™, 29MT , 31MT™, 35MT , 37MT capacity with ammeter (and voltmeter). -
Page 4: Electrical Fundamentals
1-9. BATTERIES. Batteries are perishable devices that wear out 1. Voltage. Voltage is the electrical pressure or force that causes at some point in time. With use, they deteriorate and eventually current or electrons to flow through a conductor. The voltage become incapable of performing their important job. - Page 5 NOTE The use of digital voltmeters is highly recommended for the 7.5 V following reasons: • Digital voltmeters are generally more accurate than analog (needle movement) instruments. 8.5 V • Digital readings need no interpretation; everyone sees the same number. •...
- Page 6 12.5 -12.5 DIGITAL VOLTMETER DIGITAL VOLTMETER CONNECTED CORRECTLY CONNECTED INCORRECTLY IN RELATIONSHIP TO IN RELATIONSHIP TO POLARITY POLARITY (VALUE CORRECT BUT MINUS SIGN WILL SHOW TO ALERT OPERATOR THAT LEADS ARE REVERSED) DP-1008 FIGURE 1-3. Correct and Incorrect Polarity Readings 10 AMPS OR LESS LOAD DP-1009 FIGURE 1-4.
- Page 7 CLAMP-ON TYPE AMMETER OHMETER OPEN DP-1011 FIGURE 1-6. Clamp-On Type Ammeter 1-20. MEASURING RESISTANCE WITH THE OHMMETER. DP-1012 ohmmeter is used to measure electrical resistance. The unit of FIGURE 1-7. Analog Ohmmeter Showing measure is the ohm. The ohmmeter is connected across the unit Open Circuit or portion of the circuit for which the resistance is to be measured.
- Page 8 EXAMPLES .450 COIL DIODE 0.00 DP-1015 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 DP-1014 by each circuit.
- Page 9 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.
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Page 10: Diagnosis Charts
S E C T I O N I I 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... -
Page 11: Undercharge Symptoms
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 TIGHTEN BELT TO MANUFACTURER TENSION SPECS LOCKED TEST BATTERIES CHECK PULLEYS FOR (PAGE 11) LOCKED BEARINGS START VEHICLE... -
Page 12: Milled Pinion Symptoms
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 NO VOLTS FROM SOLENOID “S” TERMINAL TO GROUND – ENGAGE START SWITCH SYMPTOMS CONTINUE REMOVE STARTER –... -
Page 13: Testing
S E C T I O N I I I Diagnostic Testing 3-1. TESTING FLOODED LEAD ACID d. Estimate battery temperature and check recorded voltage against following table. MAINTENANCE FREE BATTERIES WITH A HYDROMETER EYE Temp. 0F Min. Volts CAUTION When handling batteries, wear face or eye protection and e. -
Page 14: Test Procedure
3-5. TEST PROCEDURE e. Check recorded voltage against following table for electrolyte temperature. Disconnect Temp. 0F NOTE Min. Volts If battery has threaded terminals, use terminal adapters or verify you are testing on the lead pads not the threaded terminals. f. - Page 15 Slow or sluggish cranking may be caused by high resistance in the 2. Read and record negative cable voltage drop, (V5) then turn battery cables or connections, especially in cold weather. After all off carbon pile. batteries test well and the terminals are clean, check the battery 3.
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Page 16: Battery Cable Test With Dual-Battery Locations
3-10. BATTERY CABLE TEST WITH FIRST SET DUAL-BATTERY 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: SECOND SET 3-11. - Page 17 NOTE exceeds maximum, loss is excessive. This may be caused by loose terminals, corrosion, too small a wire, switch located too far For starters with an integral magnetic switch, use the test from starter, or worn out magnetic switch. Perform Wiring Test, procedures specific to those starters.
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Page 18: Magnetic Switch Circuit Test
4. Magnetic switch contactor voltage loss (V11) shall not exceed Test 0.2 volts for 12- or 24-volt system. 1. Push starter button with key on. 5. Replace magnetic switch if contactor voltage loss is excessive. 2. Turn on and adjust carbon pile to 100 amp load (60 amp if 24-volt system). -
Page 19: Starter Replacement Determination
3-19. TEST PROCEDURE. NOTE Magnetic switch that does not close or drops out too soon IGNITION can be caused by high resistance or open circuit in the control PUSH BUTTON circuit. MAGNETIC SWITCH NOTE VOLTAGE (13) Leave the S lead disconnected to prevent engine from cranking during these tests. -
Page 20: Alternator Wiring Test
NOTE 4. If vehicle now starts properly, make sure starter mounting bolts are tight and proceed to Alternator Wiring Test. 24-volt systems must be connected to a temporary 12-volt configuration as described for Battery Cable Test, paragraph 3-23. AVAILABLE CRANKING VOLTAGE. -
Page 21: Alternator Replacement Determination
3-28. TEST COMPLETION. Remove carbon pile and voltmeter. 3-30. ALTERNATOR VOLTAGE OUTPUT TEST. Conduct this test at For 12-volt systems, proceed with Alternator Replacement shop temperature (See Figure 3-9). Determination. For 24-volt systems, proceed as follows: Connect 1. Reconnect temporary 12-volt system back to 24-volt system. 1. -
Page 22: Completion Of All Tests
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. -
Page 23: Summary
S E C T I O N I V 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. -
Page 24: Appendix
S E C T I O N 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 –... -
Page 25: Overcrank Protection (Ocp) Circuit Check
Connect to same ground point as standard circuit (may be through relay or fuel pressure switch) Thermostat Leads (2) Motor Thermostat Connections DP-1029 DELCO REMY STARTERS WITH OVERCRANK PROTECTION 5-2. OVERCRANK PROTECTION (OCP) CIRCUIT CHECK With voltage-limiting, the batteries are connected so that the charging current is divided and each battery receives only the To check the thermostat in the OCP circuit for continuity, detach charging current it can accept at the charger’s voltage. -
Page 26: Group Charging On Current-Limiting Or Series Chargers
To prevent undercharging or overcharging and battery damage on 5-5. GROUP CHARGING ON VOLTAGE-LIMITING OR PARALLEL the charging rack, the following procedures are recommended: CHARGERS 1. Visually inspect all batteries for cracked covers or cases; NOTE replace obviously damaged batteries. The following recommendations are for batteries with electrolyte and plates at room temperatures of 55˚... -
Page 27: Heavy Duty Diagnostics Procedures Data
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 _______________________________ _______________________________ _______________________________ (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... - Page 28 NOTES __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ Page 26...
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- Page 30 13975 BorgWarner Drive Noblesville, IN 46060 U.S.A. www.delcoremy.com For Customer Support, call: 1.800.372.0222 M13101 04/20...
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