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

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Summarization of Contents

Introduction and Description
Equipment Required for Diagnostics
Lists necessary tools and equipment for diagnostic tests.
Battery Basics for Electrical Diagnosis
Discusses batteries as the starting point for electrical system diagnosis.
Electrical System Sub-Circuits
Breaks down electrical systems into four testable circuits.
Measuring Voltage with a Voltmeter
Explains how to use a voltmeter to measure electrical pressure.
Selecting the Right Voltmeter
Provides guidelines for selecting appropriate DC voltmeters.
Voltmeter Usage and Readings
Illustrates proper voltmeter usage and expected readings.
Measuring Current Flow with an Ammeter
Explains how to measure current flow using an ammeter.
Ammeter Selection Guide
Recommends clamp-on ammeters for ease and accuracy.
Ammeter Usage and Types
Demonstrates the use of various types of ammeters.
Measuring Resistance with an Ohmmeter
Explains how to measure electrical resistance using an ohmmeter.
Ohmmeter Selection and Use
Discusses selecting appropriate analog and digital ohmmeters.
Ohmmeter Applications
Illustrates typical uses of an ohmmeter, including continuity testing.
Using a Carbon Pile Load Tester
Describes the use of a carbon pile for testing circuits and batteries.
Heavy-Duty Electrical System Overview
Outlines the components of a basic heavy-duty electrical system.
Heavy Duty System Battery Types
Details different types of heavy-duty batteries and their characteristics.
Diagnosis Flow Charts
Overcharge Symptoms Diagnosis
Identifies symptoms of an overcharging electrical system.
Undercharge Symptoms Diagnosis
Lists common symptoms associated with an undercharged electrical system.
Milled Pinion Symptoms Diagnosis
Describes symptoms related to a milled pinion, such as starter spin without crank.
Diagnostic Testing Procedures
Testing Freedom Batteries
Procedures for testing Delco Remy Freedom batteries.
Testing Conventional Batteries
Procedures for testing conventional lead-acid batteries.
Battery Cable Test (Single Location)
Procedure to test battery cables for voltage drop.
Battery Cable Test (Dual Locations)
Procedure for testing battery cables in dual-location systems.
Starter Solenoid Circuit Test
Procedures to test the starter solenoid circuit for voltage loss.
Alternator Wiring Test Procedure
Tests alternator wiring for voltage loss affecting charging.
Alternator Replacement Determination
Determines if the alternator needs replacement.
Alternator Voltage Output Test
Tests the alternator's voltage output under load.
Alternator Amperage Output Test
Tests the alternator's amperage output capability.
Completion of All Diagnostic Tests
Final steps to ensure all tests are complete and wiring is restored.
Appendix and Supplementary Data
Overcrank Protection (OCP) Circuit Check
Checks the overcrank protection circuit thermostat for continuity.
Multi-Battery Charging Procedures
Discusses charging procedures for multiple batteries.
Group Charging (Series Chargers)
Procedures for group charging using current-limiting chargers.
Group Charging (Parallel Chargers)
Procedures for group charging using voltage-limited chargers.
Heavy Duty Diagnostic Data Tables
Provides tables for recording diagnostic data like voltage losses.

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