Remy 39MT GEAR REDUCTION HEAVY DUTY STARTING MOTORS User Manual download pdf

INSTALLING 38MT & 39MT GEAR REDUCTION HEAVY DUTY STARTING MOTORS

WARNING!!! ALWAYS USE PROPER EYE PROTECTION WHEN PERFORMING ANY MECHANICAL REPAIRS TO A VEHICLE –

INCLUDING, BUT NOT LIMITED TO, ANY INSTALLATION AND OR REPAIRS TO THE DELCO REMY STARTING MOTORS.

FAILURE TO USE PROPER EYE PROTECTION CAN LEAD TO SERIOUS AND PERMANENT EYE DAMAGE. Only perform the

mechanical functions that you are properly qualified to perform. A professional installation specialist should handle mechanical repairs

that are beyond your technical capabilities.

DANGER!!! ALWAYS DISCONNECT BATTERY GROUND BEFORE REMOVING OR REPLACING CABLES AT THE STARTER.

FAILURE TO DISCONNECT THE BATTERY GROUND CABLE CAN LEAD TO SERIOUS INJURY.

NOTICE! Some applications use a starter with a magnetic switch (relay) directly attached. Replacing it with a starter

without an attached magnetic switch (relay) is not recommended. It requires installing a separately mounted switch (relay)

and potentially upgrading the solenoid control circuit wiring. The separately mounted switch and wiring must meet or

exceed a current rating of 300 amperes for 12V starters and 200 amperes for 24V starters.

FOLLOW ENGINE AND/OR VEHICLE MANUFACTURER'S INSTRUCTIONS CAREFULLY WHEN REMOVING AND INSTALLING

THE STARTERS.

DRIVE HOUSING POSITION AND MOUNTING (Figures 1, 2 & 3, page 2)

 This starter with a fixed position nose less drive housing can also replace some starters with multiple position nose type drive housings.

 IT IS IMPERATIVE ALL DRAIN OPENINGS ARE LOCATED BELOW A HORIZONTAL POSITION TO ENSURE DRAINS ARE NEAR

THE BOTTOM FOR ADEQUATE DRAINAGE.

 If any shims and/or spacer washers were used with the old starter, between the starter and flywheel housings, they must be reinstalled

in exactly the same location with this starter.

 Starter cable lengths must allow for normal engine movement in all operating ranges.

REPOSITIONING INTEGRATED MAGNETIC SWITCH (IMS) (Figure 2, page 2)

 Remove the two IMS mounting screws and loosen fasteners that attach the IMS leads to the solenoid, if necessary.

 Reposition IMS by using a different set of housing switch mounting bracket holes to obtain clearance.

 Reinstall mounting screws and torque all fasteners according to values labeled in figure 2, page 2.

MOUNTING FLANGE HOLES AND MOUNTING BOLTS (Figure 3, page2)

 This starter may have either a 10.7-10.9 mm (3/8”) or 16.6-16.9 mm (5/8”) diameter mounting flange holes.

 Starters with 16.6-16.9 mm (5/8”) diameter mounting flange holes can also be mounted with 12.7 mm (1/2”) mounting bolts. Hex Head

Cap Screws (Grade 5) should always be used.

 Do not use any lock washers, star washers or soft washers with the starter mounting bolts.

ELECTRICAL CONNECTIONS (Figure 1 & 2, page 2)

 Identify and tag all leads when removing old starter so they can be properly connected on the new starter. Be sure to connect the

cables to correct solenoid terminals, because the terminals may be reversed.

 Clean or wire brush all terminals so that bare metal is exposed for good electrical connections.

 The connector for starters with optional Over Crank Protection (OCP) is the same for all series of starters.

CAUTION!! Some applications require a lead from the ECM connected to the IMS ground terminal. Starter will not function correctly if

the replacement starter has a lead connecting this terminal to the insulated/ground terminal on the commutator end.

 Remove and dispose of this starter ground lead. There must be only one lead connected to

the IMS ground terminal.

GROUNDING INSULATED STARTING MOTORS (Figures 1 & 2, page 2)

This may be an insulated starter replacing a grounded type starter. Insulated starters have a flexible cable connecting the solenoid

ground terminal to the terminal located on the commutator end of the starter (labeled Insulated/Ground). An insulated starter must have a

cable connecting this terminal to the battery ground (-) connection for the starter to function. This grounding cable between the starter

and battery should be a copper cable the same size as the positive (+) battery cable being used.

RING GEAR

If the ring gear is damaged, it must be replaced to avoid a potential premature failure and risk rejection of a warranty claim.

BATTERY COLD CRANKING AMPERES (CCA)

Excessive available CCA can damage starters. CCA rating is the current a battery can supply at “0” degree F (-18C) [See TMC RP

109A]. Following are Maximum Battery CCA Recommendations for Delco Remy Starters by Series:

38MT 12V 1875 CCA 39MT 12V 2500 CCA

24V 900 CCA 24V 1250 CCA

ELECTRICAL INSTALLATION INSTRUCTIONS (Figures 1 & 2, page 2)

REVIEW DESCRIPTIONS IN THE TABLE BELOW TO DETERMINE THE FEATURES OF THIS STARTER VS THE ONE BEING REPLACED. THE SET

OF INSTRUCTIONS TO FOLLOW MUST BE SELECTED BASED ON FEATURES OF BOTH STARTERS. NNOTE: THIS STARTER MAY ALSO BE

VERY DIFFERENT IN SIZE AND APPEARANCE THAN THE ONE BEING REPLACED.

INSTRUCTION SHEET

10511649

09SE13 C/P30500 REV3

NOTICE - Only licensed Remy International, Inc. product and component parts should be used, and the use of other parts or modifications not approved

by Remy International, Inc. will void all applicable warranties. The failure to carefully follow these Installation Instructions, set forth above, will void all

applicable warranties. DELCO REMY is a registered trademark of General Motors Corporation, licensed to Remy International, Inc. Pendleton, IN 46064.

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Summary of Contents

Page 1 - 1

INSTALLING 38MT & 39MT GEAR REDUCTION HEAVY DUTY STARTING MOTORS WARNING!!! ALWAYS USE PROPER EYE PROTECTION WHEN PER

Page 2

GROUND (-) LEAD New Starter Old Starter Install A Magnetic Switch (Relay) not attached to starter Magnetic Switch (Relay) not attached Yes B

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Remy 39MT GEAR REDUCTION HEAVY DUTY STARTING MOTORS User Manual

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