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1 bolt, read reviews...

You looking at a voltage at the relay... not sure why you think that is battery voltage... I mean, could very very well have voltage drop... could be part of the problem a poor connection, batteries could very well be at 25+ volts...

If the batteries were at 12.6 you are already "fully charged" (or close enough), the only possibility with the voltage being that high are bad batteries (no capacity), it just worked the other day so the odds of failing a load test are about 100000:1 they have the power to crank for 20 seconds...

The ops vehicle does not run, so a running voltage is not helpful right now, I do not need a copy paste from a questionable website thanks... Again, 12.6 volts is about 95% state of charge. 13.7 - 14.7 = ALTERNATOR testing... not battery. If you like attached is a chart for state of charge...

No battery when charged should be over 12.8, a battery at 12.6 volts is about 95% state of charge... OP, did you ever check for power while cranking out of the new relay, at the starter, etc etc... ya you need 2 people to check the cranking no reason to start pulling things apart until you make...