MALFUNCTION 7. 8, 9. Excessive  load  on generator  set  in  man- ual  load  reject  mode. Incorrect  load  bank output  monitored   on kilowatt  meter  as  % LOAD  SELECTOR is  sequentially rotated. Over  temperature switch  does  not disengage  when temperature  exceeds 450°  F  +  15°F. Table   4-8.   Load   Bank   Troubleshooting   (Cont) CORRECTIVE     ACTION PROBABLE    CAUSE a. Prime  load  has  exceeded — 30  Kw. b Defective  wiring  harness. -“ a. Defective  heater element(s). b Defective  wiring  harness. -“ a. Defective  thermostat switch. b. Defective  over  tempera- ture  reset  switch. c. Defective  diode  bridge. d, Defective  wiring  harness. (5)  Set  the  load  bank  OVER   TEMPERATURE switch  to  ON. (6)  Set  %  LOAD  SELECTOR    switch  to  12.5 percent  rated  load.  The  load  bank  fan  shall  operate, the  load  bank   power  indicator  shall  light,  and   the generator  set  kilowatt  meter  shall  read  approximately 12.5  percent. (7)  Sequentially   select  25,  37.5,  and   50  percent load.  Generator  set  kilowatt  meter  shall  read  ap- proximately    25,   37.5,   and    50   percent   load.   Return %  LOAD  SELECTOR     switch  to  OFF. (8) Refer to   paragraph   2-13   and  stop genera- tor  set.  Connect  an  external  load  to  generator  set equal  to  25  ±  5  percent  of  maximum   Ioad   bank  load. (9) Refer to   paragraph   2-12   and start genera- tor  set  with  external  load  connected. (10)  Set  load  bank  LOAD  REJECT   switch  to AUTOMATIC. (11)  Monitor  generator  set  kilowatt  meter  and sequentially   position  %  LOAD  SELECTOR    switch from  OFF.  Load   bank  shall  be  immediately   removed when   combined   external  load  and   selected  load  bank loads  exceed  approximately   30  KW. 4-38 a. — ^b-“ a. ^b-“ a. b. c. d. Position  ‘%  LOAD  SELECTOR    switch  to  a lower  %  load. Repair  or  replace  wiring  harness.  (Refer to   paragraph   4-43.) Test  heater  element(s)  and  replace  if  de- fective. (Refer to   paragraph   4-48.) Repair  or  replace  wiring  harness.  (Refer to   paragraph   4-43.) Test  switch  and   replace  if  defective.   (Refer to   paragraph   4-47.) Test  switch  and   replace  if  defective.  (Refer to   paragraph   4-44   d .) Test  bridge  and   replace  diode(s)   if  defective. (Higher  level  of  maintenance   required.  ) Repair  or  replace  wiring  harness.  (Refer to   paragraph   4-43.) CAUTION If  load  bank  is  not  removed  immediately when   loads  exceed  30  KW,  reduce  load bank  load  with  ‘%  LOAD  SELECTOR    switch. (12) Refer to   paragraph   2-13   and  stop genera- tor  set. 4-43.   Wiring   Harness.   (Figure   4-16) a.  Inspect  harness  for  frayed  insulation,   cracked or  loose  ty-wraps,  loose  harness  clamps  and   loose connections  to  components. b.   Repair.   Tape   frayed   insulation,   replace cra%ke=oose t y-wraps, tighten harness clamps and  tighten  all  electrical  connections.  If  a  wire  is broken   from  a  terminal  lug,  replace  lug.  Repair harnesses in accordance with   para  3-139. C. Replacement.  See    f i g u r e    4 - 1 4   and proceed as Tolloww. (1)  Removal.  Tag  and  disconnect  all  electri- cal leads and connectors from the wiring  harness   (7 or   94,   fig.   4-14)  to be removed.  The% remove all harness  clamps  (5),  (12),   (92)  and  (93)  and  the wiring  harness.