TM-3805-254-20-1
ORGANIZATIONAL TROUBLESHOOTING - CONTINUED
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
23. BOTH HEADLIGHTS DO NOT WORK - CONTINUED
WARNING
Although KEY SWITCH must be on and battery ground cable connected to test electrical circuit
voltage, turn off KEY SWITCH and disconnect battery ground cable before doing resistance tests
or replacing parts. This will keep you from getting shocked and prevent damage to parts and
equipment.
NOTE
Scrape painted surfaces to bare metal before connecting test leads to ensure correct multimeter
readings.
Step 4. Disconnect batteries (page 2-424). Check 8 wire (1) for loose, corroded, frayed, or broken
condition.
a. If 8 wire (1) is loose at circuit breaker terminal feed stud (2), tighten nut (3) using 1/2-inch
open-end wrench. If 8 wire (1) is loose at terminal (5) on secondary magnetic switch (6),
tighten nut (7) using 5/8-inch open-end wrench.
b. If wire terminal (8) is corroded, unscrew and take off nut (3), lockwasher (4), and wire terminal
(8) using 112-inch open-end wrench. Using wire brush, clean wire terminal (8) and circuit
breaker terminal feed stud (2). Place wire terminal (8) in position and screw lockwasher (4)
and nut (3) on to circuit breaker terminal feed stud (2) and tighten using 1/2-inch open-end
wrench. If wire terminal (9) is corroded, unscrew and take off nut (7), lockwasher (10), and
wire terminal (9) using 5/8-inch open-end wrench. Using wire brush, clean wire terminal (9)
and terminal (5) on secondary magnetic switch (6). Place wire terminal (9) in position and
screw lockwasher (10) and nut (7) on to terminal (5) and tighten using 5/8-inch open-end
wrench.
c. If 8 wire (1) is frayed, repair (page 2-424).
d. If 8 wire (1) is broken, 8 wire (1) must be replaced. Notify Direct Support Maintenance.
2-170
