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What does electrical shakedown testing include on a commercial truck?

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Advanced Member level 4
Oct 30, 2014
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A new truck is being built. Some of systems being built in this truck are electrical power steering (EPS) system, Antilock Braking system (ABS), Engine Control Unit (ECU), Transmission Control Unit (TCU), Body Control Module (BCM), Human Machine Interface (HMI), and Instrument cluster.

Is electrical shakedown testing performed on stationary vehicle or while driving a vehicle for certain number of miles?

My understanding is that electrical shakedown testing is minimal testing required to commence comprehensive vehicle and systems tests.

What are comprehensive electrical shakedown tests: I came up with following list so far:

1. Revolution counter reading in instrument cluster.
2. Battery voltage test (Measure battery voltage). Equipment needed voltmeter.
3. Test hazard warning light switch to ensure hazard lights work. The hazard lights must be able to operate without a key in the ignition.
4. Check brake lights turn ON when brake is applied.
5. Checks all the horns work.
6. Test wiper motor to ensure wipers works.
7. Test turn signals switches to ensure turn signals work. The indicators are only powered when the ignition switch is ON.
8. Check that cooling fan draws air from the radiator. Check that fan rotates in correct. Check the fan noise level is acceptable.
9. Test the alternator. Use a suitable ammeter to measure the theoretical maximum output current. Measure the alternator output voltage with engine off, engine running at idle, and engine running at some rpm.
10. Headlights operation.
11. High beam operation.
12. Check if brake pads are getting worn out.
13. Test service brakes.

What equipment and tools are needed to perform each electrical test?
What is the test procedure for each electrical shakedown test?
What is the expected result of each electrical shakedown test?

* Your list contains many points on vehicle inspections where required by state. See if you can get hold of their complete list.

* Be informed about current and future government requirements for vehicles. (Governments local and global.)

* A vehicle can be stationary as you idle the engine watching that it warms up to a point to turn on fan.

* An easy test of the charging system is that the battery starts the engine. Since voltage drops a few volts when cranking, observe via instantaneous bargraph voltmeter (or else an oscilloscope).

* It's not easy to test alternator current output. Call it satisfactory if it maintains 14V or so while the car runs while all accessories draw power including high beams and A/C. So much the better if it simultaneously jumpstarts another vehicle.

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