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TM 5-4210-220-12
4-24. ELECTRICAL SYSTEM - Continued
(4)
To test the wire, either use an ohmmeter connected between the two ends of the wire or connect one end
to a known 12 Vdc source and test the other end with a voltmeter.
(5)
If one wire is not conducting in a harness. lay a new wire the same size as the one that has failed,
alongside the harness. Follow the same route as the harness. Tape the new wire to the harness at least
every 12 in. (30 cm).
(6)
Remove the number sleeves from the end of the old wire and insert on new wire, or number new wire with
new sleeves.
(7)
Attach the same terminals to the new wire as are on the old wire.
(8)
Connect new wire to the terminals and check circuit functions correctly.
(9)
Cut failed wire ends out of harness so the wire cannot be reused.
REPLACEMENT
(1)
If harness has suffered severe damage due to road obstruction or other such accidents and more then 4
or 5 wires are cut through, the whole harness should be replaced.
(2)
Refer to illustration for harness routes and location of plug and sockets.
(3)
Tag and disconnect all terminals from which harness is removed to aid replacement; all new harnesses
are numbered the same as the old one and should be connected identically.
(4)
Be sure that when new harness is installed, all holes through bulkheads are protected with suitable rubber
grommets.
(5)
Be sure harness is installed with similar supports as old harness.
(6)
Be sure that no part of the harness is closer than 1 in. to moving or hot surfaces.
REPAIR
a.
Harness Repair
(1)
Badly damaged harnesses should not be repaired except in emergencies. Use butt connectors to join cut
wire ends together
(2)
A harness must be replaced if more than 5 wires are cut through.
4-424
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