ARMY TM 9-6115-641-24
AIR FORCE TO 35C2-3-456-12
OUTPUT BOX/ENGINE HARNESS.
4-4-1. Testing. Set multimeter for ohms and test individual wires for continuity. Refer to Wiring Diagram FO-2 for wire
Shut down generator set.
Open left side engine access door and disconnect negative battery cable.
Remove control box assembly, paragraph 2-212.
Remove front housing panel, paragraph 2-18-1, tag and disconnect electrical leads to fuel float module (20,
Figure 2-21), fuel level sender (4), and auxiliary fuel pump (54).
Open right side engine access door, tag and disconnect electrical leads from engine heater plugs, refer to TM
9281 525224, starter motor (including ground wires at mounting bolt), starter solenoid, battery charging al-
ternator (9, Figure 25), and magnetic pickup (7, Figure 225).
Remove left fan guard, paragraph 2701.
On left side of engine, tag and disconnect electrical leads from fuel transfer pump (6, Figure 222), coolant high
temperature switch (5, Figure 225), fuel solenoid (17), coolant temperature sender (4), low oil pressure switch
(1), oil pressure sender (2), and DEAD CRANK switch (22).
Remove bolt (12, Figure 225), nut (14), and clamps (15) and (23).
Tag and disconnect electrical leads to AC circuit interrupter relay (4, Figure 216).
Tag and disconnect electrical leads to voltage reconnection switch (14).
Tag and disconnect electrical leads to pre-heat relay (8).
Tag and disconnect electrical leads to cranking relay (6).
Open load terminal access door, tag and disconnect wire 100E from terminal GND of load output terminal board
(13, Figure 2-26).
Tag and disconnect main generator leads from rear side of terminal board (16, Figure 411).
When removing assembly, use extreme care not to drop attaching hardware
down onto generator unit. Serious damage to equipment could result.
Remove screws (12) and nuts (13) securing terminal board (14) to output box assembly.
Remove screws (15) securing terminal board (16) to output box assembly.
Remove screws (17), washers (18), nuts (19), current transformer (20), and output box/engine harness (21)
from output box assembly and generator set.
Inspect wiring harness for burned, bent, corroded, and broken terminals.
Inspect connectors for cracks, corrosion, stripped threads, bent or broken pins, and obvious damage.
Inspect wire insulation for burns, deterioration, and chafing.
Replace damaged terminals and connectors.
Replace wires with damaged insulation and those that do not indicate continuity.
Position output box/engine harness (21, Figure 411) in output box assembly and generator set.