CHAPTER 5 WIRING HARNESS REPAIR INSTRUCTIONS

CHAPTER 4 HOUSING GROUP REPAIR INSTRUCTIONS

Figure 5-1. AC Power Control 50/60 Hz Wiring Harness

TM-5-6115-545-34 Generator Set Diesel Engine Driven Tactical Skid Mtd. 30 Kw 3 Phase 4 Wire 120/208 and 240/416 Volts Manual
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CHAPTER 5 WIRING HARNESS REPAIR INSTRUCTIONS 5-1. General. Electrical interconnection of control devices and indicators is accomplished through wiring harnesses. Wires in the harnesses are bundled and secured to prevent unnecessary movement and chafing, and to conserve space. Internal wiring harnesses for the relay boxes, kits and other electrical assemblies are also provided in this section. 5-2. Wiring Harness Removal and Inspection. a. Refer to Operator and Organizational Mainten- ance Manual for harness removal procedures. b. Refer cooperator and Organizational Main- tenance Manual for inspection procedures. 5-3. Wiring Harness Repair and Rebuild. a. Repair. (1) Repair procedures for individual wires are covered in the Operator and Organizational Mainten- ance Manual. (2) If a wiring harness has sustained damage to 30 percent or more of the wires in the harness, the wiring harness must be completely rebuilt. b. — of the set. Rebuild. (1) Figures 5-l through 5-40 are illustrations wiring harnesses installed on the generator (3) Refabricate anew wire harness using the illustration for dimension and the wire run list for proper wire connection. (4) If a wiring harness cannot be identified, compare it with the illustrations until proper identi- fications made. Check numbers stamped on wires against those in the wire run list to insure proper identification before proceeding with refabrication. (5) Wiring shall be neatly laced through the use of self-locking nylon straps, located at intervals not to exceed three inches, and also at each wire break out. (6) Soldering shall be in accordance with re- quirement 5 of MIL-STD-454 using SN60 solder. (7) Wire numbering shall be in accordance with MIL-W-5088, except that length between ad- jacent groups of numbers shall not exceed six inches. (8) Cut insulation tubing in one-half inch pieces and install around wires at pins of connec- tors and receptacles. (9) Install nylon filler plugs MS25251-16 in unused openings of connectors. 5-4. Installation. Refer to Operator and Organizational Maintenance Manual for installation procedures. (2) Each illustration includes a wire run list providing wire origination, destination, identifica- tion number, wire length, and preparation require- ments, and end preparation. Find numbers (circled) related to specific components. 5-1

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