CHAPTER 4. ELECTRICAL SYSTEM MAINTENANCE

TM 5-2420-224-34

CHAPTER 4

ELECTRICAL SYSTEM MAINTENANCE

This chapter illustrates and describes procedures for maintenance of the electrical system. A list of tasks

contained in this chapter is shown below.

Page

Altemator Bearings Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2

Regulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4

Starter Brushes Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6

Main Wiring Harness Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1o

Alternator Cable Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-28

Crane Mast Floodlight Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . .

4-30

Trailer Wiring Harness Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-32

Dome Light Cable Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-34

Hazard Warning Light Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . .

4-36

Auxiliary Headlight, Front Composite Light, and Blackout Driving Light

Wiring Harness Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-38

STE/lCE-R Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-40

Forklift Wiring Harness Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-42

Forklift Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-44

Forklift Power Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-46

Forklift Connector to Fuse Holder Wiring Harness Replacement . . . . . . . . . . . . . . .

4-46

Cab Floor separation Point to Hydraulic Suspension Lockout Wiring

Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-50

Cab Floor Separation Point to Rear Wall Wiring Harness Replacement . . . . . . . . . .

4-52

Fuse Holder to Hydraulic Suspension Lockout/Rear Wall Wiring

Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-54

Fuse Holder to Hydraulic Suspension Lockout/Rear Wall Wiring

Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-56

Frame Wiring Harness Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-58

Suppressor Filter Electrical Lead Replacement . . . . . . . . . . . . . . . . . . . . . . . .

4-66

Cap Plug Connector to Heater Panel Switch and Master Light Switch

Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-68

Chassis Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-70

Throttle Solenoid Electrical Leads Replacement . . . . . . . . . . . . . . . . . . . . . . .

4-74

4-1