TM 5-6115-593-12TO 35C2-3-463-1by twisting them together. Solder theconnection and wrap with electricaltape.(2) If a wire is broken from a terminal lug,replace the lug. If a wire is brokenfrom a connector, resolder andreassemble.CAUTIONUnder no condition leave the bareconnection exposed.(3)If a break in the wire is inaccessiblewithin the wiring harness, disconnectit at both ends and tape both ends.Lace a new lead of the same gaugeand insulation outside the harnessand connect it to the proper terminalsor pins. Properly tag both ends of allreplacement wires.(4) If more than 30 percent of the harnesswires are defective, refer to nexthigher level of maintenance forreplacement.Section XI. MAINTENANCE OF AC-DC CONTROL BOX ASSEMBLY4-28. GENERAL. This section contains inspection,test, and replacement information for the AC-DC ControlBox Assembly. See figure 4-17, 4-18 and 4-19 andproceed as follows:a. Gain access to the components of the AC-DC Control Box by loosening six captivescrews on the AC-DC control panel (3,figure 4-17). Use the top and bottomlatches to release and open the side door(73, figure 4-17) to the AC-DC Control Box.b. Inspection. Inspection components of theAC-DC Control Box Assembly for defective,broken, or cracked components. Inspectwiring for loose connections.c. Testing. Testing of components of the AC-DC Control Box Assembly is describedunder the appropriate heading in paragraphs4-29 through 4-35.d. Repair. Repair by replacement ofcomponents which do not function properlyduring testing. Small dents in the controlpanel may be hammered out and refinished.WARNINGSet MAINTENANCE LOCKOUT switch toLOCKOUT. Disconnect negative cablefrom batteries. Remove external power.Load terminals of generator set circuitbreaker (CB2 may still be energized withbus voltage.e. Replacement. Replace components whichdo not function properly in step c (Testing)as indicated in following paragraphs.Replace control panel (3) by first looseningsix captive screws, then tag and disconnectleads and remove screws (1). Install newcover panel by installing panel using screws(1), then reconnect leads, remove tags, andtighten captive screws.4-29. CIRCUIT BREAKER CB103 (42, figure 4-18)a. Test.(1) Place circuit breaker switch to the ON(closed) position.(2) At the rear of the panel, remove leadsfrom one side of circuit breaker.(3) With an ohmmeter (Rx1 scale), testcircuit breaker for closed contacts. Ifmeter indicates an open circuit,replace circuit breaker.(4) Place circuit breaker in OFF position(open). Using ohmmeter on Rx1scale, test circuit breaker for opencontacts. If meter indicates a closedcircuit replace circuit breaker.4-50
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