IK0800523 ­ General Circuit Load Testing and Voltage Drop Test

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IK0800523
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Availability: ISIS, FleetISIS

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ELECTRICAL SYSTEM

Created:

Current
Language:

English

Last
6/8/2016
Modified:

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NONE
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Author:

3/10/2016

James
Santos

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Title : General Circuit Load Testing and Voltage Drop Test
Applies To : All Models

CHANGE LOG
Please refer to the change log text box below for recent changes to this article:
06/08/2015 - Initial Article Release




DESCRIPTION
This document will guide the user through performing general circuit load testing and voltage drop testing.

SYMPTOM(s)
Diagnostic Trouble Code(s) & Dashboard Indicator Light(s):

DTC/Light

Description

N/A
N/A

Customer Observations or Concerns:
NA

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IK0800523 ­ General Circuit Load Testing and Voltage Drop Test

Page 2 of 6

SPECIAL TOOL(s) / SOFTWARE
Tool Description

Tool Number

Fluke DVOM

ZTSE4357

Head Lamp

GE9006

Comments

Instructions

Recommended

SERVICE PARTS INFORMATION
Kit Description

Part Number

Quantity
Notes
Required

NA

DIAGNOSTIC STEP(s)

To prevent property damage, personal injury, and / or death, keep flames or sparks away
from vehicle and do not smoke while servicing the vehicle’s batteries. Batteries expel
explosive gases.

To prevent personal injury and / or death, always wear safe eye protection when
performing vehicle maintenance.

Step Action
#1 DIAGNOSTIC:
Identify power and ground circuit being tested, load will need to be applied in
series Please refer to figure 1. With circuit set up as figure 1. Does
the head lamp illuminate?
Note: It is good practice to wiggle test harness while observing lamp. If lamp
flickers possible bad connection or intermittent defect is present in harness.

Decision
Yes.
Proceed to step 2
No.
Make certain test leads are connected
correctly.
If so, you have isolated a circuit concern
that needs to be further
diagnosed /repaired.

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IK0800523 ­ General Circuit Load Testing and Voltage Drop Test

Page 3 of 6

Figure 1: Voltage Check After Headlamp

Although resistance-free connections, wires and cables would be ideal, most of them will contain at
least some voltage drop. Use the following as maximum limits recommendations:
•
•
•
•

0.00V across a connection
0.20V across a wire or cable
0.30V across a switch
0.10V at a ground

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IK0800523 ­ General Circuit Load Testing and Voltage Drop Test

Step Action
DIAGNOSTIC:

Page 4 of 6

Decision
Yes.
You have isolated a circuit concern that
needs to be further diagnosed /repaired.

With head lamp illuminated measure voltage from B+ to head lamp input
terminal and record voltage. Refer to figure 2

Is voltage drop greater than .5V?

No.
Proceed to step 3

#2
B+ side of circuit does not
exhibit evidence of fault or failure.

Figure 2: Voltage Drop Reading on B+ Side

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IK0800523 ­ General Circuit Load Testing and Voltage Drop Test

Step Action

Page 5 of 6

Decision

DIAGNOSTIC:

Yes.
you have isolated a circuit concern that
needs to be further diagnosed /repaired.
With head lamp illuminated measure voltage from head lamp output to ground. No.
Refer to figure 3.
Ground side of circuit does not
exhibit evidence of fault or failure.
#3
Is voltage drop greater than .5V?

Figure 3: Voltage Drop Reading on Ground Side

REPAIR STEP(s)
N/A

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IK0800523 ­ General Circuit Load Testing and Voltage Drop Test

Page 6 of 6

WARRANTY INFORMATION
N/A

OTHER RESOURCES
Master Service Information Site
Fluke® Voltage Drop Article

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Comments

Created
Date

You received the following feedback From: dy14825 - Matt Rahn Email Address: [email protected] Job Classification: SE008, Service
6/8/2016
DY14825 Technician Dealer: TRU­NOR TRUCK CENTRES Feedback: Thank you for providing a simple explanation that I can use to show other techs
8:11:35 AM
who don't understand this procedure. Is there any way we can make other articles that explain the other simple DMM procedures?

Copyright © 2016 Navistar, Inc.

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