ELECTRIC SYSTEM RT540E SERVICE MANUAL
3-4 Published 4-20-2015, Control # 502-01
MAINTENANCE
General
Electrical system maintenance includes troubleshooting and
replacement of damaged components. Observe standard
wiring practices when replacing components.
General Troubleshooting
NOTE: Make voltage checks at terminations when
components are installed and operating. Make
continuity checks (with batteries disconnected)
when components are isolated or removed.
Troubleshoot per the following guidelines:
1. First, use reported symptoms to identify a problem or a
suspect component.
2. Test the suspect component per instructions in this
section. The instructions identify the circuit breakers and
components and guide you from the easiest and most
likely problems to the hardest and least likely problems.
3. Using a multimeter, test the circuit for continuity if you
suspect a broken circuit or for voltage if you suspect a
power problem. Check the electrical schematic and
wiring diagram for most accurate wiring information.
4. If the component proves faulty, replace it with a known
working component.
5. If wiring proves faulty, this is typically the result of
another failure within the electrical system. Identify and
investigate the root cause of failure. Make necessary
component repairs as outlined in the following sections.
Proceed to make appropriate wiring fault repair. Wiring
repairs must be made using Manitowoc approved
materials.
6. Splicing sections of broken wire must have terminations
that meet minimum pull test requirements listed in table
3-5. Splices must be completely covered with adhesive
lined shrink tubing. Tubing must extend beyond any bar
conductors by at least ¼”.
Table 3-5
Minimum Pull Values (In lbs)
7. After troubleshooting, test the repaired harness. Verify
the circuit works properly.
Troubleshooting Swivel-Caused Electrical
Problems
Troubles common to the swivel are improper mounting,
foreign material between the brushes and slip rings,
incorrect wiring from the swivel to the components, incorrect
wire size, worn brushes, improper spring tension on the
brush assembly, and loose setscrews on the slip ring
assembly. Refer to the electrical schematic and wiring
diagram for slip ring connections and amperages.
Connector Troubleshooting
The cause of an electrical problem may be a loose or
corroded connection in the pin or socket connectors. Check
the connectors to ensure that the pins and sockets are
properly seated and engaged. If the pins and sockets show
any signs of corrosion, use a good quality electrical contact
cleaner or fine sandpaper to clean them. When the pins or
sockets show signs of arcing or burning, it indicates another
failure within the electrical system that might cause the
condition. Identify and investigate the root cause of the
failure, make necessary component repairs and then
proceed to make the necessary wire terminal repairs.
CAUTION
If it is necessary to perform electrical maintenance on live
or hot circuits, remove all rings, watches, and other
jewelry before performing maintenance as serious burns
result from accidental grounding or shorting circuits.
CAUTION
Ensure the batteries are disconnected before performing
any maintenance on an electrical circuit which is not fused
or when performing continuity checks.
Never replace original wiring with wiring of a smaller size
(gauge).
CAUTION
Many steps in the troubleshooting procedures require
testing live (energized) components. Perform these steps
observing good safety practices to avoid electrical shock
injury.
Wire Gauge Single Wire
Two Wire
Termination
24 10 8
22 15 10
20 20 17
18 30 20
16 40 30
14 60 50
12 70 60
10 80 70
89080
6 100 90
4 140 120
Reference Only
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