I've got a little problem, Ags. I'm working on a 1980s HMMWV that has an electrical issue. I would like some help from any of you who have first-hand experience. Long story as short as possible below.
Unit has been operational in the past.
Unit saw a lot of sand and salt water exposure with the Teams.
Unit just recently started having issues upon start. Before this it was working and running fine with a jump start.
First time, was using a slave cable to get power from another Humvee. The two were jumped together for about 20-30 minutes to charge batteries. Turned ignition to "wait" position; heard some sort of ticking noise; "wait" light went off, move ignition to start. Engine fired and was running while I disconnected the slave cable. Engine quit, then smoke started coming from OLI on winch. (Note: Ignition switch installed at the time did not automatically spring back out of the "start" position. It had to be turned back manually.) See photo below.
The place where it caught fire is at the upper left corner. Got batteries disconnected and doused the fire.
I disconnected the two cables from the starter that go to the winch. (Repairing that is a separate issue that should be pretty straight forward.) Cleaned up the connector posts on the starter and repaired one of the ground connections.
Second time, slave cable connected; batteries hooked up; ignition switch to "wait"; smoke started coming out from under the "dog house" inside. That black object with the "t" top is an RPM sensor that might have experienced the smoke test. See photo below. Looks a little crispy, don't it?
Third time, no slave cable; batteries connected, and the diagnostic connector forward of the gear shift started smoking. I disconnected the batteries, removed the cap on the connector, and now you can see in the photo below what I saw when I did so.
It'd be nice to know to what that pin connects.
Obviously, there may be a short somewhere, but it would be helpful to know where to start. I have a new ignition switch. I plan on getting a new RPM sensor. I'm going to do a couple of starter checks to make sure the positive strap from the starter to the solenoid hasn't lost its insulation and is creating a short.
Engine is a 6.2L version. Batteries have a little less than 10 volts each. High amp alternator works fine. Is this a starter issue? a control box issue? a battery issue? If you've got some operational maintenance experience, I'd like to hear your ideas.
PM me at mark96ss at hotmail dot com. Thanks in advance.
Unit has been operational in the past.
Unit saw a lot of sand and salt water exposure with the Teams.
Unit just recently started having issues upon start. Before this it was working and running fine with a jump start.
First time, was using a slave cable to get power from another Humvee. The two were jumped together for about 20-30 minutes to charge batteries. Turned ignition to "wait" position; heard some sort of ticking noise; "wait" light went off, move ignition to start. Engine fired and was running while I disconnected the slave cable. Engine quit, then smoke started coming from OLI on winch. (Note: Ignition switch installed at the time did not automatically spring back out of the "start" position. It had to be turned back manually.) See photo below.
The place where it caught fire is at the upper left corner. Got batteries disconnected and doused the fire.
I disconnected the two cables from the starter that go to the winch. (Repairing that is a separate issue that should be pretty straight forward.) Cleaned up the connector posts on the starter and repaired one of the ground connections.
Second time, slave cable connected; batteries hooked up; ignition switch to "wait"; smoke started coming out from under the "dog house" inside. That black object with the "t" top is an RPM sensor that might have experienced the smoke test. See photo below. Looks a little crispy, don't it?
Third time, no slave cable; batteries connected, and the diagnostic connector forward of the gear shift started smoking. I disconnected the batteries, removed the cap on the connector, and now you can see in the photo below what I saw when I did so.
It'd be nice to know to what that pin connects.
Obviously, there may be a short somewhere, but it would be helpful to know where to start. I have a new ignition switch. I plan on getting a new RPM sensor. I'm going to do a couple of starter checks to make sure the positive strap from the starter to the solenoid hasn't lost its insulation and is creating a short.
Engine is a 6.2L version. Batteries have a little less than 10 volts each. High amp alternator works fine. Is this a starter issue? a control box issue? a battery issue? If you've got some operational maintenance experience, I'd like to hear your ideas.
PM me at mark96ss at hotmail dot com. Thanks in advance.