Service Manual

Workman HD SeriesPage 8 − 6Electrical System
Electrical System Quick Checks
Battery Test (Open Circuit Test)
Use a multimeter to measure the voltage between the
battery terminals.
Set the multimeter to the DC volts setting. The battery
should be at a temperature of 60F to 100F (16C to 38C).
The ignition key should be in the OFF position and all ac-
cessories turned off. Connect the positive (+) meter lead
to the positive battery post and the negative (−) meter
lead to the negative battery post.
NOTE: This test provides a relative condition of the bat-
tery. Load testing of the battery will provide additional
and more accurate information (see Battery Service in
this Chapter).
Voltage Measured
Battery Charge Level
12.68 v (or higher) Fully charged (100%)
12.45V 75% charged
12.24V 50% charged
12.06V 25% charged
11.89V 0% charged
Charging System Test
This is a simple test used to determine if a charging sys-
tem is functioning. It will tell you if a charging system has
an output, but not its capacity.
Use a multimeter set to the DC volts setting. Connect the
positive (+) meter lead to the positive battery post and
the negative (−) meter lead to the negative battery post.
Leave the test leads connected and record the battery
voltage.
NOTE: Upon starting the engine, the battery voltage will
drop and then should increase once the engine is run-
ning.
NOTE: Depending upon the condition of the battery
charge and battery temperature, the charging system
voltage will increase at different rates as the battery
charges.
Start the engine and run at high idle. Allow the battery to
charge for at least three (3) minutes. Record the battery
voltage.
An example of a charging system that is functioning:
At least 0.50 volt over initial battery voltage.
Initial Battery Voltage = 12.30V
Battery Voltage after 3 Minute Charge = 12.85V
Difference = +0.55V
Glow Plug System Test (Workman HDX−D)
This is a fast, simple test that can help to determine the
integrity and operation of your Workman HDX−D glow
plug system. The test should be run anytime hard start-
ing (cold engine) is encountered on a diesel engine
equipped with a glow plug system.
Tool(s) required: Digital multimeter and/or inductive
Ammeter (AC/DC Current Transducer).
Properly connect the ammeter to the digital multimeter
(refer to manufacturers’ instructions) and set the multi-
meter to the correct scale. With the ignition switch in the
OFF position, place the ammeter pickup around the
main glow plug power supply wire and read the meter
prior to activating the glow plug system. Adjust the meter
to read zero (if applicable). Activate the glow plug sys-
tem by turning the ignition switch to ON and record the
multimeter results.
The Workman HDX−D glow plug system should have a
reading of approximately nine (9) amps per glow plug
(27 amps total). If low current reading is observed, one
(or more) of the glow plugs is faulty.