ELECTRICAL TROUBLESHOOTING - TM-9-2320-386-24-1-10085

TM 9-2320-386-24-1-1

0012 00

Electrical Troubleshooting (Contd)

MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

CAUTION

During installation of battery terminals, ensure positive clamps

are installed on positive (+) posts and negative clamps are

installed on negative (-) posts. Failure to connect clamps to correct

posts will reverse polarity of circuitry and may cause damage to

rectifier diodes in alternator, vehicle wiring, and radios (if

equipped).

Do not use a hammer during installation of battery terminals or

damage may result. Spread battery terminal open.

Step 1. Open door of battery compartment, remove battery box, and place on running board

(TM 9-2320-386-10). Visually check connection of battery cables.

Ensure battery cables are correctly connected to batteries (WP 0121 00).

Step 2. Visually check batteries for cracks and leaks. Check terminal posts for corrosion and

breaks (TM 9-6140-200-14).

a. Replace any battery that is cracked, leaking, or has broken terminal posts

(WP 0122 00).

b. If terminal posts or cable clamps are corroded, use soda and water solution to

neutralize battery acid. Remove battery ground cable no. 7 from negative post first.

Remove cable clamps from battery posts (WP 0121 00). Clean posts and clamp

mating surfaces to bright metal. Install cable clamps.

c. If battery terminals are clean and malfunction still exists, go to test 1.

Test 1. Check specific gravity of each cell before adding distilled water.

Step 1. Using optical battery tester, which requires no temperature compensation, check

specific gravity of electrolyte in each cell (TM 9-6140-200-14).

If specific gravity of any cell is below 1.255, battery must be replaced or recharged.

Add distilled water as necessary after checking battery. Charge battery as necessary

(TM 9-6140-200-14).

Step 2. Check specific gravity of cells after battery has been charged (TM 9-6140-200-14).

Each cell in a battery must test within 0.025 points of each other. If specific gravity of

any cell is lower than 1.255 [correct to 80F (27C), if necessary] after 25 hours of

charging, replace battery (WP 0122 00).

Test 2. Disconnect battery ground cable (WP 0121 00) and test battery cables as follows:

Step 1. Set multimeter to measure continuity.

Step 2. Check for continuity of battery cables 6 and 68 and for worn or frayed insulation.

a. If continuity is greater than 1 ohm, replace or repair battery cables (WP 0121 00).

b. If insulation is worn or frayed, replace or repair battery cables (WP 0121 00).

Step 3. Check continuity of battery ground cable 7 to STE/ICE-R.

a. If resistance measures greater than 1 ohm, clean cable 7 connection at

STE/ICE-R.

b. If continuity is still greater than 1 ohm, replace or repair battery cable

(WP 0121 00).

Step 4. Connect battery ground cable (WP 0121 00).

0012 00-2