ELECTRIC SYSTEM RT880E SERVICE MANUAL
3-12 Published 11-10-2014, Control # 524-00
NOTE: If the correct readings were not obtained in the
Engine On Tests, perform the following two tests.
Voltage Drop Test
Positive Side
1. Set the multimeter to the 2 volt range.
2. Connect the positive (
+) lead to the alternator output ter-
minal and the negative (
–) lead to the battery positive
terminal or post. Do not connect the meter to the battery
cable.
3. Run the 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 indicates
loose, corroded, or broken connections.
Negative Side
1. Set the multimeter to the 2 volt range.
2. Connect the negative (
–) lead to alternator case and the
positive (
+) lead to the battery negative terminal or post.
Do not connect the meter to the battery cable.
3. Run the engine at 2000 RPM.
4. Load system with carbon pile load or lights and heater
blower.
Allowable drop is 0.1 to 0.3 volts. Higher voltage indicates
loose, corroded, or broken connections.
If any voltage drop is greater than the normal range,
troubleshoot the system and repair any problems.
After correcting any problems, perform the Engine On Tests
again. If satisfactory results are not obtained, remove the
alternator and bench test.
Alternator Replacement
Removal
1. Ensure that the key switch has been off for 2 minutes.
2. Turn the battery disconnect switch to the OFF position.
3. Remove the ECM power fuse.
4. Remove negative battery cables.
5. Open the engine compartment.
6. Tag and disconnect the electrical leads from the termi-
nals on the alternator.
7. Using a 1/2 in drive bar/ratchet, turn the tensioner, below
the alternator, clockwise to remove tension from the belt.
Slip the belt off of the alternator pulley, then let the ten-
sioner return to its normal position.
8. Remove the alternator mounting capscrews. Remove
the alternator.
Installation
1. Inspect the belt. Verify it has no cracks or other damage.
Replace damaged belt as needed.
2. Install the alternator using the mounting bolts and wash-
ers. Torque bolts to 27 lb-ft (36.6 Nm).
3. Install the belt on all engine pulleys except the alternator
pulley for now.
4. Turn the tensioner clockwise. Slip the belt onto the alter-
nator pulley, then carefully return the tensioner to its nor-
mal 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 lon-
gest 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 ten-
sion 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 32 lb-ft (43 Nm).
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. Turn battery
disconnect switch to the connected position.
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 12 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 off for 2 minutes.
2. Turn the battery disconnect switch to the OFF position.
3. Remove the ECM power fuse.
4. Remove negative battery cables.
5. Open the engine compartment.
6. Tag and disconnect the electrical leads from the termi-
nals on the starter.
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