ELECTRICAL SYSTEM GRT9165 SERVICE MANUAL
3-12
Published 10-01-2020 Control # 699-00
Table 3-4. Deutsch Extraction Tool Table
Table 3-5. Deutsch Crimping Tool Table
Alternator/Charging System
Troubleshooting
Test batteries, alternator, and cables any time there is a
problem with the charging system.
Required Tools
The following tools are required to diagnose the charging
system:
Visual Check
• Belts: tight, in good condition, not frayed, cracked or
glazed.
• Pulley: tight, aligned with other pulleys, not glazed.
• Alternator mounting bolts and wiring connections: clean
and tight, no signs of heat damage.
• Batteries: terminals and cables, clean and tight, no
corrosion or signs of heat damage.
• Check alternator fuse if Alternator Charge Lamp is
illuminated on the steering column display while engine
is running.
Engine Off Tests
Batteries
1. Disconnect batteries and test each battery individually.
2. Check electrolyte level if possible.
3. Using a multimeter, measure voltage across terminals. If
should read 130 A to 135 A.
NOTE: If correct readings were not obtained in the Engine
On Tests, perform the following two tests.
Voltage Drop Test
Positive Side
1. Set multimeter to the 2 volt range.
2. Connect positive (
+) lead to alternator output terminal
and negative (
–) lead to battery positive terminal or post.
Do not connect meter to battery cable.
3. Run engine at 2000 rpm.
4. Load system with carbon pile load or lights and heater
blower. Allowable drop is 0.2 to 0.5 volts. Higher voltage
drop indicates loose, corroded, or broken connections.
Description Deutsch Part Number Manitowoc Part Number
12 gauge wire 114010 9999100194
16 gauge wire 0411-204-1605 9999100195
8-10 gauge wire 114008 7902000012
4-6 gauge wire 114009 7902000009
Description Deutsch Part Number Manitowoc Part Number
12, 14, 16, 18, 20 gauge wire HDT-48-00 9999100808
4, 6, 8, 10 gauge wire HDT04-08 9999100842
Equipment Example
Manitowoc
Part No.
Digital Multimeter Fluke
® 177 9999101763
Carbon Pile Load
Test er
Autometer
® SB5 9999101765
Current Clamp
Meter
Fluke
® 336 9999101764
DANGER
Do not smoke or allow sparks or open flame near
batteries, they can explode.
When working with batteries always wear protective
clothing, gloves and eye protection. Batteries contain
corrosive liquids that can burn skin and eyes and destroy
clothing.
Remove rings, watches or other jewelry before working
with batteries. A battery can produce a short-circuit
current high enough to weld a ring or similar to metal
causing severe burns
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