TM 9-2540-207-14&P
5.5.6
Power and Logic Wiring Harnesses (continued)
Installation
1.
Inspect Secondary Air duct and replace if necessary. Ensure duct is attached to Top Housing end with two 1"
metal spring clamps.
Note: Ensure Power and Logic Harnesses are installed on their respective sides of
the Top Housing.
2.
Install Power Wiring Harness connectors J1, J6 and Resistor R1 down through the top of the Top Housing at the
Fuel Pump end.
3.
Install Logic Wiring Harness connectors J1, J6 and Thermocouples T1 and T2 down through the top of the Top
Housing at the Fuel Pump end.
4.
Install MS Power connector (J2) by running it to the front of the Top Housing and inserting it through the hole in
the Top Housing. Ensure that the MS Power connector keyway is positioned so that when the connector is
secured, the key is located on the bottom side of the connector. Apply Loctite 242 (blue) to two (2) screws, place
two (2) lock washers on these screws and secure the MS Power connector by inserting the screws into the
connector from the front of the Top Housing. Tighten with a #1 cross-tip screwdriver.
5.
With the Top Housing on its side, fuel inlet facing upwards, pull the Power Harness tight, and re-install Logic
Harness and Power Harness rubber grommets onto the Feed-thru Plate. Seal around grommet with RTV.
6.
Using a #2 crosstip screwdriver, secure the Feed-thru Plate to the Top Housing with four (4) self tapping screws
installed from the top side of the Top Housing into the Feed-thru Plate which is on the underside of the Top
Housing.
7.
Re-install the Power Main Capacitor (C2) into the metal clamp located beside the Fuel Pump. Tighten the bolt
found on the side of the Capacitor clamp B. Using Loctite 242 (blue) and a screwdriver, tighten the screw
holding the Power Inductor (L1) clamp to the Burner Fan Plate.
9.
Attach the Power Harness connectors as follows:
Connector J3 to the Burner Fan Driver Board
Connector J5 to the Fuel Injector and rotate the Fuel Injector so that the Connector is pointing
downwards between the Burner Fan Motor and the Burner Fan Plate
Connector J4 to the Fuel Pump
10.
Attach the Logic Harness connectors as follows:
Connector J2 to the Diagnostic Display Board E
Connector J4 to the Fuel Pressure Transducer
11.
Ensure Logic Connector J3 (Data Comm. connector) is tucked inside the Top Housing.
12.
Install the wires in the Top Housing alongside the Burner Fan Motor. Tuck all wires and connectors neatly in the
Top Housing using cable ties if necessary. Ensure the wires DO NOT extend out of the Top Housing.
13.
Attach one P-Clip to the Power Harness wiring bundle and attach the Harness to the bottom of the Top Housing
using Loctite 242 (blue), a #2 cross-tip screwdriver and a screw. Note: The Fuel Injector Resistor (R1) ground
lug is secured with this screw (ref Figure 5-5.3). Do not tighten P-clip screw until following final length
adjustments.
14.
Attach one P-Clip to the Logic Harness wiring bundle and attach the Harness to the bottom of the Top Housing
using Loctite 242 (blue), a #2 cross-tip screwdriver and a screw. Do not tighten P-clip screw until following final
length adjustments.
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