Published 4-20-2015, Control # 502-01 3-7
RT540E SERVICE MANUAL ELECTRIC SYSTEM
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 and isolate the negative battery cables.
5. Open the engine compartment.
6. Tag and disconnect the electrical leads from the
terminals on the alternator.
7. 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 and tag all wires. Remove the alternator link
capscrew and the mounting capscrew. Remove the
alternator.
Installation
1. Inspect the belt. Verify it has no cracks or other damage.
Replace damaged belt as needed.
2. To assemble the alternator, the mounting components
must be tightened in the following sequence.
a. Alternator-to-alternator bracket capscrew.
b. Lower brace-to-alternator capscrew.
c. Lower alternator brace-to-water pump capscrew.
d. Torque brace-to-alternator bolt, see Fasteners and
Torque Values (pg 1-11). Torque alternator-to-
alternator bracket, see Fasteners and Torque
Values (pg 1-11).
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 10 to 13 mm (3/8
to 1/2 inch) with your thumb. (Or, using a belt tension
gauge, verify there is 267 to 578 N (60 to 130 lb) 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 43 Nm (32 lb-ft).
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 24 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 and isolate 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 43 Nm (32 lb-ft).
2. Connect the electrical leads to the terminals as tagged
during removal.
3. Connect the batteries.
4. Install the ECM power fuse.
5. Turn the battery disconnect switch to the ON position.
6. Close the engine compartment.
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 improperly with the flywheel, that the starter’s
gear hasn’t disengaged from the flywheel after the
ignition switch is in the ignition (run) position, or some
other problem. Install starter properly as needed.
Reference Only
To Next Page
Loading...
Need help?
General
