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NEWS | Feb. 16, 2021

Stryker: Charging System Diagnostics and Troubleshooting

Strykers across the fleet are experiencing battery charging problems. These problems lead to vehicles being non-mission capable (NMC) and readiness taking a big hit.

Soldiers can take action now to prevent these problems, mainly by following troubleshooting procedures to the letter to make sure the charging system problems are correctly diagnosed.

Here are some good tips to help keep troubleshooting on track and keep the charging system doing its job:
  • Always follow the procedures outlined in TM 9-2355-311-13&P (Sep 16) for the M1126 ICV Stryker,  TM 9-2355-326-13&P (Sep 16) for the M1135 NBCRV Stryker, TM 9-2355-321-13&P (Sep 16) for the M1128 MGS Stryker and TM 9-2355-363-13&P (Sep 16) for the double v-hull Stryker when troubleshooting. If you follow the steps as described, it’ll lead you to the right diagnosis and corrective action. This will help avoid an unnecessary voltage regulator, generator/alternator or harness replacement due to misdiagnosis.
  • The first step in troubleshooting a Stryker charging system is always to start at the batteries and the generator/alternator, NSN 6115-01-578-9318. Ensure that all cables are serviceable, tightly secured, properly connected, and have the proper voltage and amperage. Without adequate voltage, the regulator and the generator/alternator may not energize.   
  • Many times the Stryker’s generator/alternator is diagnosed as having a bearing failure. Keep in mind that petroleum leaks, coolant and water in the hull, an inoperable engine bay fan, and lack of preventive maintenance in the engine compartment can lead to contaminated fluids getting hot and forming a mist that’s drawn into the generator/alternator, shorting out the regulator. And the buildup of contaminants and dust in the generator/alternator leads to generator bearing failures being misdiagnosed. 
  • Keep up with the semi-annual and annual PMCS outlined in the following TMs to ensure the engine bay fan is working properly:
    • TM 9-2355-311-13&P (Sep 16) for the M1126 ICV Stryker 
    • TM 9-2355-326-13&P  (Sep 16) for the M1135 NBCRV Stryker  
    • TM 9-2355-321-13&P  01 (Sep 16) for the M1128 MGS Stryker
    • TM 9-2355-363-13&P  (Sep 16) for the double v-hull Stryker
  • Don’t stand on top of the generator/alternator! That can damage the W459 cable, NSN 6150-21-921-7124. So watch your step when working on or around the generator/alternator.
Don't stand on generator
Don't stand on generator
TB1 is the power terminal that supplies the power to the W459. Always ensure the W459 lead to TB1 on the bulkhead is securely connected to the positive cable post. Verify the battery cable protective cover for the TB1 is present and serviceable. It won’t charge without power.
  • The W452 cable, NSN 6150-21-921-7126, can get damaged while installing new batteries if the ground wire isn’t first removed from the voltage regulator before removing the old batteries from the battery box.
W452 cable can get damaged during battery installation
W452 cable can get damaged during battery installation
  • Take care not to damage the climate control thermistor’s W451 cable, NSN 6150-21-921-7604, during battery removal and installation.
  • There can be a false reading of the regulator indicator on the annunciator panel caused by the W4 harness wire, NSN 6150-21-913-4480, that leads to the isolator. If the W4 harness isn’t connected properly, the REG (regulator) light will illuminate on the annunciator panel, but still show that the vehicle is charging on the gage cluster. This commonly leads to a misdiagnosis of a bad regulator or annunciator panel.
Make sure W4 harness is connected 
Make sure W4 harness is connected 
Note 1: Be careful removing and installing the annunciator panel while troubleshooting to avoid damaging the driver’s instrument panel wiring harness. Also, install wiring harness W4 in the routing noted during removal.
Note 2: Don’t bend cables or cords excessively or to a sharp radius. That can cause the sheathing to break, exposing wires and resulting in short circuits and damage to cables, cords and equipment. Connecting or disconnecting cables while the power is turned on can cause electric shock or arcing. Make sure the power is off when connecting or disconnecting cables to avoid injury to personnel and damage to equipment.
  • Slave Starting: Before slave starting, turn on the interconnect and try to start the vehicle. If you have to slave start the vehicle, turn off the interconnect before attempting to slave start. Also, make sure all C4ISR/C5ISR components are turned off, including the Force XXI Battle Command Brigade and Below (FBCB2), Enhanced Position Location Reporting System (EPLRS), Defense Advanced GPS Receiver (DAGR) and Vehicle Intercommunication System (VIS).Make sure the power pack interface (PPI) unit indicator LED illuminates green too.

    Once the vehicle is running, unhook the slave and ensure the interconnect switch is off. Driving with the interconnect switch on can damage the battery isolator, NSN 5950-01-578-1415, or the batteries themselves.

    Note: To avoid damaging the starter, never engage the start switch if the engine is running. Also, never operate the starter for longer than 15 seconds at a time. Allow two minutes between starting attempts to allow the starter to cool down.        
If the Stryker’s engine doesn’t start after three attempts, do the troubleshooting steps listed in the -10 TM.
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