Manitowoc Grove 5540F Service Manual page 59

5540F/YB5515 SERVICE MANUAL
TROUBLESHOOTING
Finding a problem in the electrical system is not difficult if you
know basic electricity and understand the arrangement of
t h e e l e c t r i c a l s y s t e m . U s e t h e w i r i n g d i a g r a m s i n
Schematics/Wiring Diagrams as your guide.
Accurate testing equipment is also necessary. The
instruments normally used are a voltmeter, ammeter,
ohmmeter and test light.
Many times the problem can be found by visual inspection of
the components in the circuit. Corrosion on terminals, loose
connections or bad wiring are the causes of many problems.
Table 3-5
Charging System Troubleshooting
Problem
Alternator does not charge.
High charging rate (battery at full
charge).
Low charging rate.
GROVE
Each circuit in the system has a fuse for protection against
overloads. Remember that a burnt fuse is an indication of an
overload or SHORT circuit, not an OPEN circuit.
If you did not find the cause of the problem during the visual
inspection, use a voltmeter to check the voltage at several
points in the circuit, or measure voltage drop across the
component. Normally, the best method is to start at the
furthest component in the circuit and move backwards
toward the power supply. An ohmmeter can be used to
measure the resistance in any component. Remember to
disconnect the component from the power supply before you
connect the ohmmeter.
Possible Cause
1. Alternator belt loose or broken.
2. Worn brushes or open brush leads
or connections.
3. Open circuit, short circuit or
ground stat or winding.
4. Fault in voltage regulator.
5. Short circuit or open circuit in
rectifier diodes.
6. Open circuit or short circuit in rotor
(field) winding.
7. Wires connected wrong, loose, or
broken.
8. Dirty slip rings or bad slip ring
connections.
1. Low electrolyte level in battery.
2. Fault in wiring system.
3. Loose or dirty connections.
4. Malfunction in voltage regulator.
1. Loose or worn alternator belt.
2. Bad alternator.
3. Bad battery.
4. Low electrolyte level.
5. Short circuit in system.
6. Worn alternator.
7. Malfunctioning voltage regulator.
8. Low engine speed.
Published 10-21-2010, Control# 198-04
ELECTRIC SYSTEM
Solution
1. Replace and/or tighten
specification.
2. Replace or repair alternator.
3. Replace alternator.
4. Replace voltage regulator.
5. Replace or repair alternator.
6. Replace alternator.
7. See wiring diagram. Repair or
replace wires.
8. Inspect slip rings. Clean or repair
as required.
1. Add distilled water.
2. Repair or replace faulty wiring.
3. Clean and tighten connections.
4. Replace voltage regulator.
1. Adjust or replace belt.
2. Replace or repair.
3. Replace battery.
4. Add distilled water.
5. Check and repair.
6. Test, replace or repair alternator.
7. Replace the voltage regulator.
8. Run engine at higher speed.
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