Published 08-25-09, Control # 077-04 3-5
RT9130E SERVICE MANUAL ELECTRICAL SYSTEM
2. Try to turn on the head lights, tail lights, marker lights,
dome light, work light, or gauge lights and panel lights to
verify the batteries have at least some charge. If none of
these lights comes on, suspect the batteries. Charge
batteries as needed, or replace the batteries if you can
jump-start the crane from another crane.
3. If you hear the starter relay clicking repeatedly, power is
reaching the starter, but not enough. Suspect the
batteries. Charge batteries as needed, or replace the
batteries if you can jump-start the crane from another
crane.
4. Check Fuse 53 (100 amp) inside battery box. If fuse is
blown, replace it.
5. Turn the ignition switch to RUN (1). Check the voltmeter.
If it doesn’t move (but the head lights, tail lights, marker
lights, dome light, work light, or gauge lights and panel
lights will come on), suspect the ignition switch and the
power circuit to it starting at the ignition switch fuse
(Fuse 8). Repair or replace circuit, switch, or fuse as
needed.
6. If the battery, fuses, 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
superstructure control module (connector A)
through carrier control module (connector A) to
starter relay (K301). 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 start 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,
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,
check fuses 54, 55, 56, and 57 in the battery box.
Replace if required. 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 each battery puts out 12 volts minimum. Charge
batteries as needed so they can supply a minimum
excitation voltage to the engine’s charging system.
4. Verify there is a minimum of 12 volts at the alternator
from the batteries, and that the alternator is properly
grounded.
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.
NOTE: If the alternator overcharges (voltmeter reads high,
light bulbs burn out quickly), look for a ground
where one shouldn’t exist. If external wiring checks
out, replace alternator. (The alternator probably
has an internal ground or a faulty internal voltage
regulator.)
Troubleshooting Accessories
If the crane’s engine starts and charges properly, but none of
its components except the horn or lights work, the accessory
circuitry may be faulty. Check as follows:
1. Turn the ignition switch to the ACC (3) position. Try to
turn on the cab circulating fan, the heater fan, the
defroster fan, or the windshield wipers or washer. If none
of these come on (but the head lights, tail lights, marker
lights, dome light, work light, or gauge lights and panel
lights will come on), there is an accessory circuitry
problem.
2. Check the primary power circuit to the accessory relays
K1 and K2. Make circuit repairs as needed.
3. If the problem remains, check the ignition switch and the
accessory control circuit from the ignition switch through
the coil of the accessory relays K1 and K2 to ground.
Turn the ignition switch to the ACC (3) position and listen
for audible click of relays K1 and K2. If neither relay
clicks, then there is no power through the switch when it
is in the ACC (3) position. Replace ignition switch if there
is no power through it when in the ACC (3) position. If
one relay clicks and the other does not, check continuity
of the coil of the relay that does not click. If there is no
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