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Published 9-04-2014, Control # 422-08
RT765E-2 SERVICE MANUAL SERVICE MANUAL ELECTRICAL SYSTEM
MAINTENANCE
General
Electrical system maintenance includes troubleshooting and
replacement of damaged components. Observe standard
wiring practices when replacing components.
Visual Inspection and Replacement of Electrical
Harnesses and Cables
Visually inspect all electrical harness and cable assemblies
every month or at 250 hours of service life for the following:
• Damaged, cut or deteriorated harness loom covering.
• Damaged, cut or abraded individual wires or cable
insulation.
• Exposed bare copper conductors.
• Kinked, crushed, flattened harnesses or cables.
• Blistered, soft, degraded wires and cables.
• Cracked, damaged, or badly corroded battery terminal
connections.
• Inspect all machine ground connections for damaged
terminals or excessive corrosion.
• Other signs of significant deterioration.
If any of these conditions exist, evaluate the harness
assemblies for repair or replacement. For replacement of
harness assemblies, refer to your Manitowoc Crane Care
Parts Manual.
At the same service interval, visually inspect all Controller
Area Network (CAN) nodes and electrical junction boxes for
the following:
• Damaged or loose connectors.
• Damaged or missing electrical clamps or tie straps.
• Excessive corrosion or dirt on the junction box
assemblies.
• Loose junction box mounting hardware.
If any of these conditions exist, address them appropriately.
Ambient temperature, humidity and other factors affect the
life of electrical harness and cable assemblies. Use the
following information for the inspection and replacement of
these assemblies:
• Cranes operating in climate zone “C” should have the
harness and cable assemblies replaced after 10,000
hours of service life.
• Cranes operating in climate zones “A” or “B” with high
ambient temperatures could see electrical service life
reduced by 25% to 40%. It is recommended to replace
these assemblies after 8000 hours of service life.
• Cranes operating in climate zones “D” and “E”, cold
climates, should expect a degradation of mechanical
properties, long term exposure to these cold
temperatures will negatively impact service life.
Therefore, it is recommended these electrical harnesses
and cable assemblies be inspected regularly as service
life may be less than 10,000 hours.
• Cranes operating in salt water climates could see a
significant reduction in service life. Therefore it is
recommended for these electrical harnesses and cable
assemblies to be inspected regularly as service life may
be less than 8,000 hours.
DANGER
When possible, ensure the battery is disconnected
before performing any maintenance on an electrical
circuit.
If it is necessary to perform electrical maintenance on
live or hot circuits, remove all rings, watches, and other
jewelry before performing maintenance as serious
burns may result from accidental grounding or shorting
circuits.
CAUTION
Never replace original wiring with wiring of a smaller
size (gauge). Fire or other damage to the machine may
result.
CAUTION
Ensure that the battery cables are disconnected from
the batteries before loosening any electrical
connections.
Reference Only
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