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5-5 Heavy Duty Diagnostic Procedures Data

Section 3-7 BATTERY CABLE TEST

W/500 AMP LOAD (FROM FIGURE 3-3)

5-3

POSITIVE CABLE

LOSS

NEGATIVE CABLE

LOSS

NEGATIVE CABLE

LOSS

(MAX. 0.500 V)

Section 3-27 ALTERNATOR WIRING LOSS

AMP LOAD = ALTERNATOR RATED OUTPUT (FROM FIGURE 3-8)

POSITIVE CIRCUIT

LOSS

V24

NEGATIVE CIRCUIT

LOSS

V25

ALTERNATOR

CIRCUIT LOSS

(MAX. 0.500 V)

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

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

FIRST WIRE

LOSS

SECOND WIRE

LOSS

V10

MAG SWITCH

LOSS

V11

TOTAL SOLENOID

CIRCUIT LOSS

(MAX. 1.00 V)

(AMP LOAD AND MAXIMUM VOLTAGE LOSSES SHOWN AR FOR 12V SYSTEMS.)

Delco Remy is a registered trademark licensed by General Motors Corporation.

new diagnostic manual 4/5/05 9:48 AM Page 5-3

This document, and more, is available for download from Martin's Marine Engineering Page - www.dieselduck.net

Содержание 37MT

Страница 1: ...Diagnostic Procedures Manual new diagnostic manual 4 5 05 9 47 AM Page u This document and more is available for download from Martin s Marine Engineering Page www dieselduck net ...

Страница 2: ...rcuit Test 3 4 3 18 Magnetic Switch Circuit Test 3 6 3 21 Starter Replacement Determination 3 6 3 26 Alternator Wiring Test 3 7 3 29 Alternator Replacement Determination 3 8 3 33 Completion of All Tests 3 9 IV SUMMARY 4 1 V APPENDIX 5 1 Overcrank Protection OCP Circuit Check 5 1 5 2 Multi Battery Charging with Series Parallel Chargers 5 1 5 3 Group Charging on Current Limiting or Series Chargers 5...

Страница 3: ...e what caused the symptoms Actual adjustment repair or replacement procedures are provided in unit specific service bulletins and manuals 1 5 For educational purposes study of this entire manual is recommended For diagnostic purposes the flow charts in Section II will reference appropriate procedures for specific symptoms 1 6 EQUIPMENT REQUIRED To perform the tests specified in this manual the fol...

Страница 4: ...coil of the magnetic switch and back to the battery Excessive loss here can cause a no start complaint 4 Charging Circuit This consists of the wiring between the alternator and the battery and back to the alternator Excessive loss here can cause the batteries to not charge properly As noted above discharged batteries will cause other problems 1 11 SEQUENCE OF PROCEDURES It is important that the pr...

Страница 5: ...16 volts 3 24 volt vehicles 0 32 volts NOTE The use of digital voltmeters is highly recommended for the following reasons Digital voltmeters are generally more accurate than analog needle movement instruments Digital readings need no interpretation everyone sees the same number Digital instruments are generally autoranging they automatically select the proper range for the value of the reading Rev...

Страница 6: ...type is easy to use cannot be damaged by misconnection and will not damage the vehicle wiring A clamp on ammeter operates by measuring the magnetic flux produced by current flow through a conductor and translating that into amperes which are displayed on the meter readout 1 19 AMMETER USE Figures 1 9 through 1 11 illustrate the use of various types of ammeters 1 Figure 1 9 illustrates the used of ...

Страница 7: ...4 illustrate some typical uses of the ohmmeter CAUTION Typical heavy duty electrical system voltage 12 or 24 volts could produce a current flow 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 1 23 As shown in Figures 1 12 and 1 13 the ohmmeter is also useful as a conti...

Страница 8: ...s and power the vehicle s electrical accessories and loads 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 to ensure that system wiring is adequate to carry the current required by each circuit 1 28 HEAVY DUTY SYSTEM BATTERIES The battery or more common bat...

Страница 9: ...ng similar to that of Filler Cap batteries Some means of replacing water is necessary and these batteries include a plug strip or individual covers over the filler holes which are removed to add water 3 The Filler Cap Batteries Not so common any more these are lead acid batteries with antimony in the grid alloy The disadvantage of these batteries are that they require frequent servicing Maintenanc...

Страница 10: ...Project1 4 5 05 9 07 AM Page 1 This document and more is available for download from Martin s Marine Engineering Page www dieselduck net ...

Страница 11: ... THAN 15 5 V INTERNAL VOLTMETER EXTERNAL REGULATOR DEFECTIVE CHECK DASH VOLTMETER OK REPLACE ALTERNATOR USE REG SVC BULLETIN TO ISOLATE DEFECT REPAIR VOLTMETER 120 F OR MORE CK BATTERY TEMP RETEST WITH COOL CHARGED BATTERIES DEFECTIVE TEST BATTERIES PAGE 3 1 REPLACE DEFECTIVE BATTERY COMPLETE COMPLETE 119 OR LESS OK new diagnostic manual 4 5 05 9 47 AM Page 2 1 This document and more is available ...

Страница 12: ...PONENT SLOW CRANK ENGINE OK OK START VEHICLE CK ALTERNATOR VOLTAGE OUTPUT PAGE 3 8 OK BUT DISCHARGED CK CRANKING CIRCUIT PAGE 3 2 DEFECTIVE DEFECTIVE REPAIR AND VERIFY REPAIR CK STARTER SOLENOID CIRCUIT PAGE 3 4 SEE STARTER REPLACEMENT DETERMINATION PAGE 3 6 REPAIR WIRING CIRCUIT VERIFY REPAIR CK ALTERNATOR VOLTAGE OUTPUT PAGE 3 8 TEST BATTERIES PAGE 3 1 OK new diagnostic manual 4 5 05 9 47 AM Pag...

Страница 13: ...PINION CHECK REPAIR SOLENOID CIRCUIT REPAIR OR REPLACE STARTER DO NOT INSTALL VISUALLY CHECK RING GEAR MILLED TEETH REPLACE RING GEAR AND CHECK FLANGE TO FLYWHEEL DIM CHECK STARTER PER APPROPRIATE SERVICE BULLETIN OK REINSTALL STARTER AND PERFORM CIRCUIT CHECKS SEE PAGE 3 4 REPLACE STARTER AND VERIFY REPAIR REPAIR VERIFIED DEFECTIVE OK new diagnostic manual 4 5 05 9 47 AM Page 2 3 This document an...

Страница 14: ...Project1 4 5 05 9 07 AM Page 1 This document and more is available for download from Martin s Marine Engineering Page www dieselduck net ...

Страница 15: ...inspection or test as follows a Apply test load of 1 2 CCA rating 0 F in amps b After 15 seconds with load on measure and record battery terminal voltage c Turn load off d Estimate battery temperature and check recorded voltage against following table Temp F 70 50 30 15 0 Min Volts 9 6 9 4 9 1 8 8 8 5 e If recorded voltage does not meet or exceed that in table replace battery Otherwise battery is ...

Страница 16: ...rn load off e Check recorded voltage against following table for electrolyte temperature Temp F 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 f If recorded voltage does not meet or exceed that in table replace battery Otherwise battery is OK 3 6 TEST COMPLETION Clean 1 Cable ends and battery terminals with wire brush Tighten 1 Battery hold downs to specifications NOTICE Leave ba...

Страница 17: ...e loss V5 to get total cable loss V3 This loss V3 shall not exceed 12 volt system with 37 MT 40 MT 41 MT or 42 MT starter 0 500 volt maximum voltage loss 12 volt system with 50 MT starter 0 400 volt maximum loss 24 volt system with 37 MT 40 MT 41 MT 42 MT or 50 MT starter 1 000 volt 4 Replace cables or repair circuits with excessive voltage drop 3 9 TEST COMPLETION If temporary 12 volt test connec...

Страница 18: ...ire lead to which carbon pile is connected Meter will show battery voltage NOTICE 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 Solenoid Circuit Test NOTICE In the following step on a 24 volt vehicle if the temporary 12 volt system will not close the magnetic switch bypas...

Страница 19: ... record voltage V10 on voltmeter 4 Add voltage loss V10 to voltage loss V9 previously recorded to get total wire voltage loss 5 Total wire voltage loss shall not exceed 12 volt system 0 8 volt 24 volt system 1 8 volt 6 Replace and repair wiring and connections if voltage loss is excessive NOTICE Perform the following test only if the magnetic switch closed in preceding tests 3 16 MAGNETIC SWITCH C...

Страница 20: ...tch ground to frame or motor ground terminal With key on push start button and read voltage V 14 If voltage V 14 is within 1 0 volt 2 0 volts for 24 volt system of battery voltage repair magnetic switch ground lead or connections If not replace voltmeter ground lead at magnetic switch ground terminal 5 Repeat step 4 moving voltmeter plus lead to the following locations and measuring the specified ...

Страница 21: ... vehicle does not crank properly the problem must be with the starter or the engine Replace the starter and recheck to see if engine cranks properly If not then look for a mechanical problem with the engine 3 26 ALTERNATOR WIRING TEST This procedure is the first step in checking out the charging system The output of the alternator the batteries and the accessory loads with a minimum of voltage los...

Страница 22: ...ing circuits are OK conduct the following tests to determine if the alternator must be replaced NOTICE Make sure that alternator mounting hardware is secure and that belts are OK before testing alternator NOTICE Batteries shall have been satisfactorily load tested and must be near full charge with more than 12 4 Volts no load voltage 3 30 ALTERNATOR VOLTAGE OUTPUT TEST Conduct this test at shop te...

Страница 23: ...er 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 4 Repeat steps 1 and 2 If output is still zero replace the alternator 3 32 ALTERNATOR REPLACEMENT Replace alternator if either of the following conditions exist 1 Alternator output voltage exceeds 15 5...

Страница 24: ...Project1 4 5 05 9 07 AM Page 1 This document and more is available for download from Martin s Marine Engineering Page www dieselduck net ...

Страница 25: ...ified in this manual may seem to be complex and lengthy Actually with practice and experience they become quite simple As maintenance personnel gain confidence and competency with these procedures they may easily become part of routine preventative maintenance Remember two things as you improve your diagnostic efforts with this manual 1 Don t jump to early conclusions 2 Perform the diagnostic proc...

Страница 26: ...Project1 4 5 05 9 07 AM Page 1 This document and more is available for download from Martin s Marine Engineering Page www dieselduck net ...

Страница 27: ...urrent See Fig 1 for typical hook up With Parallel Chargers the batteries are connected so that the charging current is divided and each battery receives only the charging current it can accept at the charger s voltage See Fig 2 for typical hook up Because of these differences the charging procedures also differ No matter which type of charger is used differences exist between batteries age capaci...

Страница 28: ...hydrometer if reading is 1 230 or more test as outlined in Delco Service Bulletin 1B 115 If reading is below 1 230 proceed with charging procedure If fluid level is low add water to bring level sufficiently high for hydrometer readings but not to split ring then proceed with charging After charging add water to split ring B Freedom batteries Check built in hydrometer if clear or yellow replace bat...

Страница 29: ...T LOSS V25 ALTERNATOR CIRCUIT LOSS MAX 0 500 V Section 3 15 3 16 STARTER SOLENOID CIRCUIT TEST W 100 AMP LOAD FROM FIGURE 3 6 FIRST WIRE LOSS V9 SECOND WIRE LOSS V10 MAG SWITCH LOSS V11 TOTAL SOLENOID CIRCUIT LOSS MAX 1 00 V AMP LOAD AND MAXIMUM VOLTAGE LOSSES SHOWN AR FOR 12V SYSTEMS Delco Remy is a registered trademark licensed by General Motors Corporation new diagnostic manual 4 5 05 9 48 AM P...

Страница 30: ...Notes new diagnostic manual 4 5 05 9 48 AM Page 5 4 This document and more is available for download from Martin s Marine Engineering Page www dieselduck net ...

Страница 31: ...Notes new diagnostic manual 4 5 05 9 48 AM Page 5 5 This document and more is available for download from Martin s Marine Engineering Page www dieselduck net ...

Страница 32: ... U S A www delcoremy com For Customer Support call 1 800 372 0222 PRINTED ON PROCESSED CHLORINE FREE PAPER National Catalog Managers Association new diagnostic manual 4 5 05 9 47 AM Page t This document and more is available for download from Martin s Marine Engineering Page www dieselduck net ...

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