ARMY TM 9-6115-642-24
AIR FORCE TO 35C2-3-455-12
MARINE CORPS TM 09247A/09248A-24/2
SECTION II. MAINTENANCE OF CONTROL BOX ASSEMBLY
4-2 CONTROL BOX HARNESS.
4-2.1
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
4-2.2
a.
b.
4-2.3
4-2.4
a.
b.
4-2.5
a.
b.
c.
d.
e.
f.
Removal.
Shut down generator set.
Open left side engine access door and disconnect negative battery cable.
Remove control box top panel, paragraph 2-16.1.
Open storage box access door and disconnect three electrical connectors at bottom of control box.
Remove crank disconnect switch, paragraph 2-32.3.
Remove relays, paragraph 2-33.3.
Remove screws (1, FIGURE 4-10), washers (2), insulators (3), clips (4), and sockets (5) from track (20).
Remove screws (6) and nuts (7) to free terminal board (8).
Remove screws (9), nuts (10), and cap (11) to free diagnostic connector (12).
Tag and disconnect electrical leads at AC voltage regulator (21, FIGURE 2-11), shunt (27), BATTERY CHAR-
GER FUSE assembly (17), DC CONTROL POWER circuit breaker (19), overvoltage relay (30), frequency
transducer (24), short circuit/overload relay (33), resistor-diode assembly (39), CONVENIENCE RECEP-
TACLE (5) and GROUND FAULT CIRCUIT INTERRUPTER (8).
Disconnect electrical connector (13, FIGURE 4-10) to malfunction indicator (12, FIGURE 2-11) panel.
Tag and disconnect electrical leads to all indicators, switches, and lights on control paneI.
Remove screws (14, FIGURE 4-10) and nuts (15) to free harness connectors (16), (17), and (18).
Remove harness assembly (19) from control box.
Inspect control box harness wiring for breaks, damaged insulation, and loose or damaged terminals.
Inspect harness connectors, sockets, and terminal board for cracks, corrosion, stripped threads, broken pins,
and other visible damage.
Testing. Using Wiring Diagram FO-2 as a guide, check all wires for continuity with multimeter.
Repair.
Replace damaged cable assemblies, terminals, connectors, sockets, or terminal board.
Replace or ensure proper connection of all wires not indicating continuity.
Position control box wiring harness assembly (19, FIGURE 4-10) in control box.
Secure harness connectors (16), (17), and (18) to control box with screws (14) and nuts (15).
Connect all electrical Ieads to control panel indicators, switches, and lights as tagged on removal. Remove tags.
Connect electrical connector (13) to malfunction indicator panel (12, FIGURE 2-11).
Install diagnostic connector (12, FIGURE 4-10) and cap (11) with screws (9) and nuts (10).
Connect electrical leads, as tagged on removal, to GROUND FAULT CIRCUIT INTERRUPTER (8,
FIGURE 2–11), CONVENIENCE RECEPTACLE (5), resistor-diode assembly (39), short circuit/overload relay
(33), frequency transducer (24), over voltage relay (30), DC CONTROL POWER circuit breaker (19), BAT-
TERY CHARGER FUSE assembly (17), shunt (27), and AC voltage regulator (21). Remove tags.
4-7
Inspection.
Installation.
