ARMY TM 9-6115-644-24
AIR FORCE TO 35C2-3-446-12
MARINE CORPS TM 09249A/09246A-24/2
Inspect connectors for cracks, corrosion, stripped threads, bent or broken pins, and obvious damage.
Inspect wire insulation for bums, deterioration, and chafing.
Install output box harness, paragraph 4-10-5.
Shut down generator set.
Open battery access door and disconnect negative battery cable.
Remove control box assembly, paragraph 2-19-2.
Remove output box top panel, paragraph 4-8-1, step l.
Open right side engine access doors, tag and disconnect electrical Ieads from battery charging alternator, starter
solenoid, starter motor, and ether solenoid valve.
Open left side engine access doom, tag and disconnect electrical leads from coolant high temperature switch,
DEAD CRANK switch, low oil pressure switch, oil pressure sender, governor actuator, fuel injection pump, cool-
ant temperature sender, magnetic pickup, fuel level sender, fuel float module, and auxiliary fuel pump.
Open output box access door. Remove screws (4, FIGURE 4-5) and cover (5) from AC circuit interrupter relay
(40). Tag and disconnect electrical leads from cranking relay (43), current transformer (31), AC circuit interrupter
relay (40), power potential transformer (37), and voltage reconnection board (18).
Tag and disconnect electrical leads for droop current transformer (34) from terminal board (25).
Remove screws (24) and nuts (23) securing terminal boards (25) and (26) in output box.
Remove all clamps securing output box harness to generator set.
Remove output box harness (27) from output box and generator set.
a. Set multimeter for ohms.
b. Check individual wires, connectors, and terminal boards for continuity. Refer to Wiring Diagram FO-2 for wire
Replace damaged cable assemblies, terminals, connectors, sockets, and terminal boards.
b. Replace wires with damaged insulation and those that do not indicate continuity.
a. Position output box harness (27, FIGURE 4-5) in output box and generator set.
b. install all clamps, as removed, securing output box harness in generator set.
Secure terminal boards (25) and (26) in output box with screws (24) and nuts (23).
d. Connect electrical leads for droop current transformer (34) to terminal board (25) and remove tags.