TM 5-3805-254-20-1
ORGANIZATIONAL TROUBLESHOOTING - CONTINUED
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
24. ONE HEADLIGHT DOES NOT WORK.
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.
Steps 1 thru 7 are for low-beam headlights.
Steps 8 thru 13 are for hi-beam headlights.
Steps given are typical for left and right side headlights.
Step 1. Pull apart wire connectors (1 and 2). Set multimeter to 20 vdc scale. Connect red test lead to wire
terminal (3) on wire connector (1) and black test lead to ground. Have assistant push LIGHTS switch
handle (4) up to on position. Check for 11 to 13 vdc on multimeter. Have assistant push LIGHTS switch
handle (4) down to off position. Disconnect test leads.
a. If multimeter does not read 11 to 13 vdc, go to step 2.
b. If multimeter reads 11 to 13 vdc, go to step 4.
Step 2 . Unscrew and take off two wingnuts (5) and junction box cover (6). Set multimeter to 20 vdc scale.
Connect red test lead to terminal (7) on junction box (8) and black test lead to ground. Have assistant
push LIGHTS switch handle (3) up to on position. Check for 11 to 13 vdc on multimeter. Have assistant
push LIGHTS switch handle (3) down to off position. Disconnect test leads.
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