Published 4-20-2015, Control # 502-01 3-5
RT540E SERVICE MANUAL ELECTRIC SYSTEM
When replacing wire terminals, use the proper crimp tool to
ensure the proper crimping method. Refer to the tables at the
end of this section listing tools necessary for connector
maintenance. These tables list common tools; however,
contact Manitowoc CraneCare to ensure the proper crimp
tool is available.
Because the pins and sockets are crimped to the wires, it is
not possible to remove them. Using the proper extraction
tool, remove the pin(s) or socket(s) from the plug or
receptacle. Cut the wire as close to the pin or socket as
possible. After cutting the pin or socket off, the wire will most
likely be too short. Using a wire that is too short will allow
pressure to be applied to the pin or socket and wire where
they are crimped when the pin or socket is inserted in the
plug or receptacle. Splice a short length of wire to the short
wire according to the guidelines in the General
Troubleshooting section.
Troubleshooting Engine Starting Problems
1. Verify the battery terminals are connected and clean,
none of the fuses are blown, the transmission is in
neutral, and the machine is fueled.
2. Try to turn on the head lights, tails lights, marker lights,
dome light, work light, or gauge lights and panel lights to
verify the battery has at least some charge. If none of
these lights comes on, suspect the battery. Charge
battery as needed, jump-start the crane or replace the
battery when possible.
NOTE: The crane is a 24V machine which requires a 24V
source for jump starting.
3. If you hear the starter relay clicking repeatedly, power is
reaching the starter, but not enough; suspect the battery.
Charge battery as needed, jump-start the crane or
replace the battery when possible.
4. If the problem remains, troubleshoot the starter lockout
relay. Use service tool for starter lockout input signal to
CCM11. Also, check starter lockout relay to ensure it is
energized.
5. Using the service tool (see “Using Service Tool
Section”), check for proper Keyswitch input signals and
Start output signals. With the Service Tool connected to
the crane A channel, Select View, Cab, Steering
Column. Watch the Keystate value for each position of
the Keyswitch:
0=OFF
1=ON
2=START
6. If the battery, fuses, secondary circuit, ignition switch,
and power circuit to the ignition switch check out, do one
of the following:
a. If you hear no noise when you try to turn the starter,
troubleshoot the start circuit (ignition switch, electric
shifter, and wiring from ignition switch to starter
relay). Make repairs as needed.
b. If the engine still won’t start, and you hear no noise
or just a single click, suspect the starter.
Troubleshoot the starter circuit from the starter relay
through the starter solenoid to the starter motor and
ground. Make repairs as needed. If the starter
solenoid or the starter motor is faulty, replace the
starter.
c. If the starter engages but can’t turn the engine (and
the lights dim, signaling power drain during start
attempt), check the starter’s feed circuit from the
batteries for resistance. If the resistance is high,
greater than .002Ω, make repairs. If the circuit
checks out, replace the starter. If the engine still
won’t start, suspect a seized engine.
d. If the starter turns the engine, but it still won’t start,
suspect a fuel problem. Ensure fuel system can
draw fuel from the tank and pump it to the engine;
make repairs as needed.
e. If the engine starts, then shuts down, suspect a fuel
problem. Ensure fuel system can draw fuel from the
tank and pump it to the engine; make repairs as
needed.
7. Refer to the engine manual for further instructions.
NOTE: If the starter won’t disengage during running, verify
the starter is mounted properly so its gear won’t
mesh with the engine’s flywheel when not trying to
start engine. Troubleshoot the starter relay and
ignition switch for closed contacts. If these
components check out, replace the starter.
Troubleshooting Engine Charging Problems
1. Verify battery terminals are connected and clean and all
wires in the charging system are in good repair and are
connected properly.
2. Verify the alternator belt is properly installed and is
under proper tension.
3. Verify the battery puts out 24 volts minimum. Charge
battery as needed so the battery can supply a minimum
excitation voltage to the engine’s charging system.
4. Verify when the crane is running that the alternator is
putting out a minimum of 24 volts DC on the voltmeter.
5. Replace the alternator if the other conditions check out.
6. Refer to the engine manual for further instructions.
NOTE: If the alternator runs noisily, check belt tension. If
problem persists, replace alternator.
Reference Only
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