TM 9-2320-361-20 Table 2-4. Electrical Troubleshooting. MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION BATTERY SYSTEM 1. ALL VEHICLE ELECTRICAL SYSTEMS INOPERATIVE WARNING Battery acid (electrolyte) is extremely harmful. Always wear safety goggles and rubber gloves when performing battery maintenance. Severe injury will result if acid contacts eyes or skin. Do not smoke, have open flame, or make sparks when performing battery maintenance. Batteries may explode causing severe injury to personnel. Remove all jewelry such as rings, dog tags, bracelets, etc. If jewelry or disconnected battery ground cable contacts battery positive post, a direct short can result, causing damage to equipment or severe injury to personnel. When removing battery cables, disconnect ground cable first. Do not allow tools to come in contact with vehicle when disconnecting cable clamps. A direct short can result, causing instant heating of tools, tool damage, battery damage, or battery explosion, and severe injury to personnel. 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 terminal. Spread battery terminal open, or damage to equipment may result. Step 1. Open door of battery compartment. Loosen two thumbscrews and slide batteries onto running board. Visually check connections of battery cables. Ensure battery cables are correctly connected to batteries (para. 4-48). Step 2. Visually check batteries for cracks and leaks. Check terminal posts for corrosion and breaks (TM 9-6140-200-14). a. b. c. Replace any battery that is cracked, leaking, or has broken terminal posts (para. 4-49). 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, clean posts, and clamp mating surfaces to bright metal. If battery terminals are clean and malfunction still exists, go to test 1. 2-77