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Never disconnect any charging unit circuit or battery circuit cable from battery when the charging unit is charging.
9S1990 BATTERY CHARGER TESTERLoad test a battery that does not hold a charge when in use. To do this, put a test load across the main connections (terminals) of the battery. For a 6, 8, or 12V battery, put a test load of three times the ampere/hour rating, (the maximum test load on any battery is 500 amperes). Let the test load remove the charge (discharge) of the battery for 15 seconds and immediately test the battery voltage. A 6V battery in good condition will show 4.5V; an 8V battery will show 6V; a 12V battery will show 9V. Each cell must show 1.6V on either a 6, 8, or 12V battery.The Special Instruction (GEG00058) with the 9S1990 Battery Charger Tester gives the battery testing procedure.Charging System
5P300 Electrical Tester. Make reference to Special Instruction (GEG02276) and to the instructions inside of the cover of the tester, when testing with the 5P300 Electrical Tester.The condition of charge in the battery at each regular inspection will show if the charging system is operating correctly. An adjustment is necessary when the battery is constantly in a low condition of charge or a large amount of water is needed (more than one ounce of water per cell per week or per every 50 service hours).Make a test of the charging unit and voltage regulator on the engine, when possible, using wiring and components that are a permanent part of the system. Off the engine (bench) testing will give a test of the charging unit and voltage regulator operation. This testing will give an indication of needed repair. After repairs are made, again make a test to give proof that the units are repaired to their original operating condition.Before starting the on engine testing, the charging system and battery must be checked as given in the Steps below.1. Battery must be at least 75% (1.240 Sp. Gr.) full charged and held tightly in place. The battery holder must not put too much stress on the battery.2. Cables between the battery, starter and engine ground must be the correct size. Wires and cables must be free of corrosion and have cable support clamps to prevent stress on battery connections (terminals).3. Leads, junctions, switches and panel instruments that have direct relation to the charging circuit must give correct circuit control.4. Inspect the drive components for the charging unit to be sure they are free of grease and oil and have the ability to operate the charging unit.Alternator Regulator (Delco)
When an alternator is either overcharging or undercharging the battery, the alternator charging rate can be adjusted. Remove the hollow head screw from the cover of the alternator regulator and use a screwdriver to turn the inside adjustment. Turn the adjustment toward the "+" to increase or toward the "-" to decrease the alternator charging rate.
ALTERNATOR REGULATORPulley Nut of Delco-Remy Alternators
Tighten the nut that holds the pulley to a torque