Manitowoc Grove RT770E, Service Maintenance Manual

Page: 135 / 357

3-11 Published 11/26/2014, Control # 447-05
RT770E SERVICE MANUAL ELECTRICAL SYSTEM
3
GROVE
If any voltage drop is greater than the normal range,
troubleshoot the system and repair any problems.
After correcting any problems, perform the Engine On Tests
again. If satisfactory results are not obtained, remove the
alternator and bench test.
Alternator Replacement
Removal
1. Ensure that the key switch has been in the OFF position
for 2 minutes.
2. Turn the battery disconnect switch to the OFF position.
3. Remove the ECM power fuse.
4. Remove the negative battery cables.
5. Open the engine compartment.
6. Tag and disconnect the electrical leads from the
terminals on the alternator.
7. Using a 1/2 in drive bar/ratchet, turn the tensioner, below
the alternator, clockwise to remove tension from the belt.
Slip the belt off of the alternator pulley, then let the
tensioner return to its normal position.
8. Remove the alternator mounting capscrews. Remove
the alternator.
Installation
1. Inspect the belt. Verify it has no cracks or other damage.
Replace damaged belt as needed.
2. Install the alternator using the mounting bolts and
washers. Torque bolts; refer to
Fasteners and Torque
Values , page 1-16 for the proper torque value.
3. Install the belt on all engine pulleys except the alternator
pulley for now.
4. Turn the tensioner clockwise. Slip the belt onto the
alternator pulley, then carefully return the tensioner to its
normal position so it puts tension on the belt. Make sure
the belt is centered on the tensioner.
5. Check belt tension at the belt’s longest span (longest
distance between pulleys). At the center point of the
longest span, push in on the belt with your thumb. Verify
you can deflect the belt no more than 3/8 to 1/2 in (10 to
13 mm) with your thumb. (Or, using a belt tension
gauge, verify there is 60 to 130 lb (267 to 578 N) of
tension on the belt in the middle of its longest span.)
Replace belt if it is too loose (overstretched).
6. Verify tensioner bolt is torqued to 32 lb-ft (43 Nm).
7. Connect the electrical leads to the terminals as tagged
during removal.
8. Close the engine compartment.
9. Reconnect the ground cables to the battery.
10. Install the ECM power fuse.
11. Turn the battery disconnect switch to the ON position.
Check
1. Run engine. Verify reading of voltmeter on front console
is 12 volts or greater. Make repairs as needed.
2. Continue troubleshooting charging system as needed if
replacement of alternator did not correct problem in
charging system.
Starter Replacement
Removal
1. Ensure that the key switch has been in the OFF position
for 2 minutes.
2. Turn the battery disconnect switch to the OFF position.
3. Remove the ECM power fuse.
4. Remove the negative battery cables.
5. Open the engine compartment.
6. Tag and disconnect the electrical leads from the
terminals on the starter.
7. Remove the bolts holding the starter to the mounting
pad. Remove the starter.
Installation
1. Place the starter on its mounting pad. Secure the starter
with the bolts. Torque the bolts to 32 lb-ft (43 Nm).
2. Connect the electrical leads to the terminals as tagged
during removal.
3. Reconnect the ground cables to the battery.
4. Install the ECM power fuse.
5. Turn the battery disconnect switch to the ON position.
Check
1. Try to start the engine. Verify the starter starts the
engine.
2. Start engine again, and listen for starter noises. Verify
there is no abnormal noise indicating the starter’s gear is
meshing properly with the flywheel, that the starter’s
gear hasn’t remained engaged to the flywheel after the
ignition switch is in the ignition (run) position, or some
other problem. Install starter properly as needed.