ARMY TM 9-6115-645-24
AIR FORCE TO 35C2-3-444-12
MARINE CORPS TM 09244A/09245A-24/2
i.
Install engine and generator assembly, paragraph 3-6.2.
j.
Install fuel tank drain valve, paragraph 2-88.2.
k.
Service fuel tank. Refer to TABLE 2-2 for proper fuel.
I.
Connect negative battery cable. Close battery access door.
SECTION IV. MAINTENANCE OF OUTPUT BOX ASSEMBLY
4-8
OUTPUT BOX ASSEMBLY.
4-8.1
Removal.
a.
Shut down generator set.
b.
Open battery access door and disconnect negative battery cable.
c.
Remove control box assembly, paragraph 2-19.2.
d.
Remove top housing section, paragraph 2-16.1.
e.
Remove air cleaner assembly, paragraph 2-73.2.
f.
Remove output box access door, paragraph 2-14.1.
g.
Remove rear housing panel, paragraph 2-18.1.
h.
Open left side engine access door, tag and disconnect electrical leads from fuel injection pump, governor
actuator, coolant high temperature switch, DEAD CRANK switch, oil pressure sender, low oil pressure switch,
coolant temperature sender, auxiliary fuel pump, and magnetic pickup.
i.
Open right side engine access door, tag and disconnect electrical leads from battery charging alternator,
starter, fuel float module, fuel level sender, and ether solenoid valve.
j.
Note locations and remove loop clamps securing output box harness to engine.
k.
Remove voltage reconnection terminal board, paragraph 4-9.1.
I.
Remove nuts (1, FIGURE 4-5), bolts (2), and output box top panel (3) from output box assembly.
NOTE
Record number and direction of wraps when removing main generator cables from transformers
to aid installation.
m.
Unwrap main generator cables from droop current transformer (34) and current transformer (31).
n.
Remove screws (4) and cover (5) from AC circuit interrupter relay (40).
o.
Tag and disconnect output cables from terminals A2, B2, and C2 of AC circuit interrupter relay (40).
p.
Tag and disconnect exciter leads F1 and F2 from terminals 1 and 2 of terminal board (26).
q.
Remove nuts (6), bolts (7), and output box assembly from generator set.
4-8.2
Installation.
a.
Install output box assembly in generator set with bolts (7, FIGURE 4-5) and nuts (6).
b.
Connect exciter leads F1 and F2 to terminals 1 and 2 of terminal board (26), and remove tags.
c.
Connect output cables to terminals A2, B2, and C2 of AC circuit interrupter relay (40), and remove tags.
d.
Install cover (5) on AC circuit interrupter (40) with screws (4).
e.
Install main generator cables onto current transformer (31) and droop current transformer (34) the same
number of wraps recorded during removal.
f.
Install voltage reconnection terminal board, paragraph 4-9.2.
g.
Connect output box harness electrical leads to battery charging alternator, starter, fuel float module, fuel level
sender, and ether solenoid valve through right engine access doors and remove tags.
h.
Connect output box harness electrical leads to magnetic pickup, coolant temperature sender, auxiliary fuel
pump, low oil pressure switch, oil pressure sender, governor actuator, fuel injection pump, DEAD CRANK
switch, and coolant high temperature switch through left engine access doors and remove tags.
4-14 Change 2
