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New update on HMMWV #2 - It's running, but the voltmeter stays in the yellow. Tested another GPC (just plugged it in while it laid on top of the engine - and, yes, I disconnected the batteries), but that wasn't the issue. Voltmeter still in the yellow. Connected multimeter to batteries while...

Repeat of above edit…… UPDATE: HMMWV #2 is running again. Four glow plugs were very swollen. Check everything and connected the batteries. Wait light stayed on 15-20 seconds. Was cold and took a bit to get started. Fired it up and let it set about 3 or 4 minutes. Voltmeter never came out...

So, speaking of PCBs, has anyone designed a reliable substitute? I was reading an old thread where someone was about to go "live" with their design. Did that ever happen?

I checked dimensions as you suggested, and when I installed the pulley, everything got sucked up tight.

No. Wanted to make sure it would spin without issue before I completed the repairs (ie. installing pulley and soldering wires).

Thanks. I have the TMs and have scanned them. Haven't had time to focus on the new generators yet.

Found the manual pump. The issue I'm having is that I don't hear an electric pump running when I turn the switch to the prime/run position. This is the 1st of 3 15Kw units that we've recently purchased. Haven't done much so far, just tinkering. It cranks, but doesn't start. Haven't had time...

I'm currently replacing the front end on one generator (broken attachment ear) and rebuilding another (attachment ears broken on both ends and replacing the rotor, as well as bearings, seals, etc.). On the one I'm rebuilding, I have it assembled, but the rotor is too far back and the aft vanes...

NSN for the engine harness? Never mind - I think I found one.

Does it need a different harness, or do you just leave the "extra" harness disconnected?

Speaking of PCBs... Have any of you ever seen and/or had experience with the brand? It has 3 cannon connectors - two in the engine bay and one under the dash. I think it was another effort to eliminate the GPC. The box is paired up with a Nartron GPC, but that shouldn't matter if the...

Chapter 1 - Green HMMWV (continued) This is the one that fried at least one PCB that we believe was caused by a faulty starter. Just received today, the kit to help us remove the broken starter bolt. Any way, I was installing a new windshield washer reservoir/pump. It came without one. I...

Chapter 2 - Tan HMMWV Different HMMWV, similar issue. Previously changed all the glow plugs - broke one tip off and had to remove the head to retrieve it, but that's another story. Been having some starting issues, but hadn't tried to start this thing for about a week or so. Decided to check...

Thanks for the clarification about the power connections. I will try to work studying the schematics into my schedule.

I looked at all those connections when I removed the starter, but I will recheck and probably put some pooky on the terminals after cleaning and tightening.

Photos of my "smart box" and diagnostic connectors. No evidence of corrosion. Also did a visual check on the GPC connectors - no corrosion. Will check connectors at battery box to ensure no corrosion and they are tight. Will check that 24v is only on the center post of engine bay...

Thanks for the tip. Most of the time our guys forget to turn off everything after they shut down the unit, causing them to have to go back and turn things off. I'm the only one who has been working with/on this unit. The lights and accessories on this unit have only been turned on for testing...

Let me try to recap. Green sticker KDS was box #1 (yellow band GPC) - it was working fine for about two weeks after I did quite a bit of work (mostly on the fuel system) to get it running. Don't know why it fried, but the starter was acted funny when it did. (As I indicated in a previous post...

correct

Haven't made much progress on finding the source of our problem. I'm tracing wires to make sure there aren't any shorts. I've learn some things. Still think the problem was the starter. Have a new starter ready to go back on, but have to deal with a broken mounting bolt first. With regards...