TM 11-6130-236-35

DEPARTMENT OF THE ARMY TECHNICAL MANUAL

DS, GS, AND DEPOT
MAINTENANCE MANUAL
CHARGER, BATTERY
PP-1451/G
(NSN 6130-00-985-8157)
This copy is a reprint which includes current
pages from Change, The title was changed as
shown above by Change 1.
HEADQUARTERS, DEPARTMENT OF THE ARMY
27 MAY 1966
TM11- 6130- 236- 35
TECHNICAL MANUAL
}
HEADQUARTERS
DEPARTMENT OF THE ARMY
No. 11- 6130- 236 WASHINGTON, DC, 27 May 1966
DS, GS, AND DEPOT MAINTENANCE MANUAL
CHARGER, BATTERY PP-1451/G
(NSN 6130-00-985-8157)
REPORTING OF ERRORS
You can help improve this manual by calling attention to errors and
recommending improvements and stating your reasons for the recom-
mendations. Your letter or DA Form 2028 (Recommended Changes to
Publications and Blank Forms) should be mailed direct to Commander,
US Army Communications and Electronics Materiel Readiness Com-
mand, ATTN: DRSEL-MA-Q Fort Monmouth, NJ 07703. A reply will be
furnished direct to you.
Paragraph
CHAPTER 1. FUNCTI ONI NG OF EQUI PMENT
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
I ndex of equi pment publ i cati ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Bl ock di agram anal ysi s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Ci rcui t anal ysi s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
2. TROUBLESHOOTI NG
General i nstructi ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Organi zati on of troubl eshooti ng procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Test equi pment requi red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Local i zi ng troubl es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Tests for open fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Addi ti onal troubl eshooti ng data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
General parts repl acement techni ques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Adjustment of vari abl e resi stors R1, R2, R3, and R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
3. GENERAL SUPPORT TESTI NG PROCEDURES
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Test equi pment, tool s, and materi al s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Physi cal tests and i nspecti ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Twenty-ei ght vol t output, regul ati on, ri ppl e, and effi ci ency test . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Two hundred and thi rty vol ts, 60-cps, i nput power test..... . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
One hundred and fi fteen vol ts, 400-cps, i nput power test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Two hundred and thi rty vol ts, 400-cps, i nput power test.... . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Test data summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
4. DEPOT OVERHAUL STANDARDS
Appl i cabi l i ty of depot overhaul standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Appl i cabl e references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Test faci l i ti es requi red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 4-4
APPENDI X REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-1
1-1
1-2
2-1
2-1
2-1
2-2
2-3
2-3
2-4
2-4
3-1
3-1
3-3
3-5
3-7
3-9
3-11
3-12
4-1
4-1
4-1
4-1
A-1
*This manual supersedes TM 11-6130-236-15, October 1965.
Change 1 i
TM 11-4130-236-35
CHAPTER 1
FUNCTIONING OF EQUIPMENT
1-1 Scope
a. Thi s manual contai ns di rect support, gener-
al support, and depot mai ntenance i nstructi ons
for Charger, Battery PP-1451/G (battery charg-
er). I t i ncl udes i nstructi ons appropri ate for trou-
bl eshooti ng, testi ng, and repai ri ng the
equi pment. I t al so l i sts tool s, materi al s, and test
equi pment requi red for mai ntenance. Functi onal
anal ysi s of the equi pment i s covered i n thi s chap-
ter .
b. The compl ete techni cal manual for thi s
equi pment i ncl udes TM 11-6130-236-12.
Note. For appl i cabl e forms and records, see paragraph 1-3,
TM 11-6130-236-12.
1-2. Index of Equipment Publications
Refer to the l atest i ssue of DA Pam 310-4 to
deter mi ne whether ther e ar e new edi ti ons,
changes, or addi ti onal publ i cati ons pertai ni ng to
the equi pment. DA Pam 310-4 i s an i ndex of
current techni cal manual s, techni cal bul l eti ns,
suppl y manual s (types 7, 8, and 9), suppl y bul l e-
ti ns, l ubri cati on orders, and modi fi cati on work
orders that are avai l abl e through publ i cati ons
suppl y channel s. The i ndex l i sts the i ndi vi dual
parts (-10, -20, -35P, etc.) and the l atest changes
to and revi si ons of each equi pment publ i cati on.
1-3 Block Diagram Analysis
(fig. 1-1)
a. I nput power of 115 vol ts al ternati ng current
(at) or 230 vol ts ac at 50 cycl es per second (cps), 60
cps, or 400 cps i s appl i ed to ci rcui t breaker CB1.
Wi th CB1 at the ON posi ti on, i nput power i s
appl i ed through the appropri ate i nput vol tage
sel ector l i nkage to transformer T1.
b. The i nput vol tage sel ector consi sts of two
shorti ng l i nks. Wi th the l i nkage i n the 115 ac
posi ti on, the two pri mary wi ndi ngs of transform-
er T1 are connected i n paral l el . Wi th the l i nkage
i n the 230 ac posi ti on, the two pri mary wi ndi ngs
of transformer T1 are connected i n seri es.
c. Bl ower fan motor B1 (rated at 115 vol ts ac,
si ngl e phase) i s connected across one of the pri -
mary wi ndi ngs of T1 to i nsure 115-vol t ac suppl y
regardl ess of i nput vol tage l i nkage connecti ons.
d. The i nput frequency sel ector l i nkage con-
si sts of four shorti ng l i nks. These l i nks are used
to connect for ei ther 50/60 or 400 cps. Al l four
l i nks must be i n the same posi ti on (ei ther 50/60
or 400). There i s one l i nk for each of the four
magneti c ampl i fi ers (L1 through L4).
e. Each of two transformer T1 secondary wi nd-
i ngs i s connected to a ful l -wave bri dge recti fi er,
wi th the gate wi ndi ngs of two magneti c ampl i fi -
ers formi ng a part of each bri dge i n conjuncti on
wi th two of the four di ode recti fi ers.
Change 1 1-1
TM 11-4130-236-35
f. The two magneti c ampl i fi ers are used i n
push-pul l as control for each ful l -wave recti fi er.
The fi rst and second control wi ndi ngs of each
magneti c ampl i fi er are used i n conjuncti on wi th
regul ati ng di odes as part of the regul ati on ci r-
cui t. Changes i n current fl ow i n the fi rst and
second control wi ndi ngs cause proporti onal i m-
pedance changes i n the gate wi ndi ngs to control
the recti fi er output vol tage.
g. The output of each bri dge recti fi er appears
across fi l ter networks consi sti ng of hal f a dual
wi ndi ng choke, L5 (secti ons A and B), and fi ve
fi l ter capaci tors. Protecti ve fuses are used to
prevent equi pment damage due to fi l ter capaci -
tor fai l ure (shorti ng).
h. The outputs of the fi l ter networks are con-
nected to bl eeder resi stors. The bl eeder resi stors
ar e connected to swi tch 28V-S2-56V. Wi th
swi tch 28V-S2-56V set to the 28V posi ti on, the
bl eeder resi stors are connected i n paral l el . Wi th
swi tch 28VS2-56V set to the 56V posi ti on, the
bl eeder resi stor are connected i n seri es.
i. I n the bl eeder resi stor ci rcui t, VOLTAGE
ADJUST control R8 i s used to feed back a control
current through a Zener di ode to the fi rst control
wi ndi ng of the magneti c ampl i fi ers. A fuse i s
used to prevent excessi ve current through the
Zener di ode. Vari ati on of the control current
through the fi rst control wi ndi ngs wi l l cause a
proporti onal change i n the output vol tage.
j. The outputs of each fi l ter network are fed to
the i nput of a contractor. The coi l s of the contrac-
tors are energi zed by the output of ful l -wave
bri dge recti fi er CR10 through CR13 i n a thi rd
secondary wi ndi ng of transformer T1.
k. When the contractors are energi zed, the fi l -
tered output of each recti fi er i s connected to the
output vol tage sel ector l i nkage. Wi th the l i nkage
set to 28V, the two outputs are connected i n
paral l el . Wi th the l i nkage set to 56V, the two
outputs are connected i n seri es. The output vol t-
age sel ector l i nkage consi sts of two shorti ng
l i nks.
l. The posi ti ve output i s coupl ed through OUT-
PUT CURRENT meter Ml shunt to the + OUT-
PUT termi nal on the front panel . (PRESS TO
READ swi tch S3 must be actuated to determi ne
the current output of the battery charger.)
m. OUTPUT VOLTAGE meter M2 i s connected
across the contacts of the output vol tage sel ector
l i nkage so that the output vol tage may be moni -
tored.
n. Separate regul ati ng ci rcui ts are provi ded for
vol tage vari ati ons due to l oad. Wi th NORMAL
CHARGE swi tch S1 set to NORMAL, the
regul ati ng ci rcui t detect changes i n the vol tage
drop across the fi l ter choke. These vol tage changes
cause current vari ati ons i n a control wi ndi ng to
mai ntai n the sel ected vol tage at a maxi mum
output current of 50 amperes for 28-vol t operati on,
or 25 amperes for 28-vol t operati on, or 25 amperes
for 56-vol t operati on. Wi th NORMAL-CHARGE
swi tch S1 set to CHARGE, the maxi mum current
output i s between 70 and 80 amperes for 28-vol t
operati on, or between 35 and 40 amperes for 56-
vol t operati on.
1-4. Circuit Analysis
(fig. 4-4)
a. Power Supply. Charger, Battery PP-1451/G
can be operated from ei ther a 115-vol t or 230-vol t
ac source, at 50, 60, or 400 cps. The i nput power i s
connected to pi ns A and B of J1 and appl i ed
through dual power swi tch and ci rcui t breaker
CB1A and CB1B to the two pri mari es of power
transformer T1. Power swi tch and ci rcui t breaker
CB1 i s the power swi tch for the equi pment and, i n
addi ti on, provi des overl oad protecti on. The two
pri mari es of T1 are i nterconnected through l i nks
at T1A and T1B to enabl e paral l el connecti on (115
vol ts ac) or seri es connecti on (230 vol ts at). Bl ower
fan motor B1 i s connected across pi ns 3 and 4 of the
pri mary of T1 and provi des cool i ng for the i nteri or
areas of the battery charger. Capaci tor Cl permi ts
B1 to be sel f-starti ng. Capaci tors C18, C19, C20, and
C21 are used to suppress radi ofrequenci es that
may be gener ated wi thi n the power suppl y.
Termi nal C on J1 provi des a common (ground)
connecti on for the i nput power.
1-2
Figure 11. Block diagram
1 - 3
TM 11-6130-236-35
(5)
(2)
(3)
(4)
1 4
115-vol t operati on to provi de 60 am-
per es of ov er l oad pr otecti on . For
230-vol t i nput power , the l i nks o f
T1A and T1B connect both pr i mar y
wi ndi ngs of T1 i n ser i es. Both 30-
amper e ci r cu i t br eak er s ar e n ow
pl aced to pr ov i de 30 amper es of
overl oad protecti on.
The ac output of T1 i s stepped
down to appr oxi matel y 42 vol ts ac.
The ac vol tage at ter mi nal s 5 and
6 of T1 i s appl i ed to a ful l -wave
br i dge r ecti fi er consi sti ng of CR1
thr ough CR4 and tor oi d gate wi nd-
i ngs of magneti c ampl i fi er s L1 and
L2. The ac vol tage at ter mi nal s 7
and 8 of T1 i s appl i ed to a second
ful l -wave br i dge r ecti fi er consi sti ng
of CR5 thr ough CR8 and the gate
wi ndi ngs of magneti c ampl i fi er s L3
and L4. A thi rd wi ndi ng of T1, ter-
mi nal s 9 and 10, provi de 30 vol ts ac
to ful l -wave br i dge r ecti fi er CR10
through CR13.
The pul sati ng dc vol tage output of
r ecti fi er s CR1 thr ough CR4 i s ap-
pl i ed to a fi l ter networ k consi sti ng
of choke L5A and fi l ter capaci tor s
C6, C7, C8, C13, and C14. The
output of CR5 thr ough CR8 i s ap-
pl i ed to a fi l ter networ k consi sti ng
of choke L5B and fi l ter capaci tor s
C9, C10, C11, C15, and C16. T h e
output of CR10 thr ough CR13 does
not r equi r e fi l ter i ng. Fuses F1
through F4 and F6 through F9 (30-
amper e r ati ng) ar e used to pr event
overl oad damage to equi pment.
Th e fi l ter ed dc ou tpu t of CR1
th r ou gh CR4 i s con n ected to a
bl eeder resi stor networ k consi sti ng
of R5, R6, and R7, to a contact of
swi tch 28V-S2-56V and to contacts
of rel ay K1. The fi l ter ed dc output
of CR5 through CR8 i s connected to
bl eeder resi stor network R8, R9, and
R10, to a second contact swi tch 28V
S256V and to contacts of rel ay K2.
The output of CR10 thr ough CR13
i s appl i ed to i ndi cator l amp DS1 and
to the coi l s of K1 and K2.
(6)
The two fi l tered dc outputs of t h e
ful l -wave br i dge r ecti fi er s can b e
connected i n ser i es (56-vol t dc op-
er ati on) or i n par al l el (28-vol t dc
oper ati on). Thi s i s accompl i shed by
posi ti oni ng both 28 DC OUTPUT 56
l i nks to the cor r ect 28 or 56 posi -
ti on. The 28VS256V swi tch must
be set to agree wi th the posi ti on se-
l ected for the 28 DC OUTPUT 56
l i nks. Wi th the 28VS256V swi tch
set to 56V, al l bl eeder resi stors are
connected i n ser i es. Wi th 28V-S2-
56V swi tch set to 28V, bl eeder resi s-
tor s R5, R6, and R7 ar e connected
i n paral l el wi th bl eeder resi stor R8,
R9, and R10.
The vol tage output of the batter y
char ger i s i n di cated on OUTPUT
VOLTAGE meter M2 wi th a r ange
of 0 to 75 vol ts dc. Th e cu r r en t
output i s i ndi cated on OUTPUT
CURRENT meter Ml wi th a r ange
of 0 to 75 amper es . PRESS TO
READ swi tch S3 must be depressed
to obtai n a readi ng on Ml .
b. Balance and Regulation Circuits (S1 Set
to NORMAL Position).
(1)
(2)
Vari abl e resi stor R1 i s adjusted t o
bal ance the outputs of both ful l -
wave br i dge r ecti fi er s by bal anci ng
the di ffer ences i n i mpedance among
the four control wi ndi ngs (termi nal s
4 and 5 of L1 thr ough L4). Var i -
abl e r esi stor R2 i s adjusted to bal -
ance the outputs of both ful l -wave
br i dge r ecti fi er s by bal anci ng t h e
di fferences i n i mpedance among the
four contr ol wi ndi ngs (ter mi nal s 6
and 7 of L1 through L4).
Output vol tage regul ati on i s achi eved
by i ni ti al l y setti ng VOLTAGE AD-
J UST R8 for th e des i r ed ou tpu t
vol tage of the battery charger. Thi s
setti ng wi l l bi as the Zener di ode
CR15 for conducti on wi th the mi ni -
mum poi nt set by R8 resul ti ng i n a
mi ni mum fl ow of cur r ent thr ough
CR15 to a maxi mum poi nt set by R8
TM 11-6130-236-35
r esul ti ng i n a hi gher val ue of cur -
rent fl ow through CR15. A decrease
i n the l oad to the batter y char ger
wi l l resul t i n an i ncrease of output
vol tage, and the potenti al across
Zener di ode CR15 i ncr eases. Thi s
i ncr ease i n potenti al acr oss CR15
wi l l cause a r i se i n cur r ent f1ow
thr ough CR15 and contr ol wi ndi ng
ter mi nal s 4 and 5. Si mul taneousl y,
an i ncrease i n current fl ows through
CR14 and control wi ndi ng termi nal s
6 a n d 7. Th e cu r r en t i n cr ea s e
th r ou gh th e con tr ol wi n di n g ter -
mi nal s 4 and 5 and 6 and 7 wi l l i n-
crease i ts i mpedance and cause a de-
crease of current fl ow through t h e
gate wi ndi ng termi nal s 1, 2, and 3.
The gate wi ndi ngs are a part of the
ful l -wave bri dge recti fi ers; therefore
the decrease of current through the
gate wi ndi ngs resul ts i n a decrease
of vol tage output of the ful l -wave
bri dge recti fi ers to the vol tage val ue
i ni ti al l y set on VOLTAGE ADJUST
R8. An i ncr ease i n the l oad to the
battery charger wi l l resul t i n a de-
cr ease of output vol tage and t h e
potenti al acr oss Zener di ode CR15
decr eases. Thi s decr eases i n poten-
ti al acr oss CR15 wi l l cause a de-
crease i n current fl ow t h r o u g h
CR15 and control wi ndi ng termi nal s
4 and 5. Si mul taneousl y, a decrease
i n cur r ent fl ows thr ough CR14 and
contr ol wi ndi ng ter mi nal s 6 and 7.
The d e c r e a s e i n current through
contr ol wi ndi ng ter mi nal s 4 and 5
and 6 and 7 wi l l decrease i ts i mped-
ance and cause an i ncr ease of cur -
r ent to fl ow thr ough gate wi ndi ng
termi nal s 1, 2, and 3. The gate
wi ndi ngs are a part of the ful l -wave
bri dge recti fi ers; ther efor e the i n-
cr ease of cur r ent thr ough the gate
wi ndi ngs r esul ts i n an i ncr ease of
vol tage output of t h e f u l l - w a v e
bri dge recti fi ers to the vol tage val ue
i ni ti al l y set on VOLTAGE ADJUST
R8.
(3) Capaci tor s C2 and C4 i n ful l -wave
br i dge r ecti fi er s CR1 thr ough CR4,
and capaci tors (23 and C5 i n ful l -
wave br i dge r ecti fi er s CR5 thr ough
CR8 ar e used to bypass the hi gh
fr equency har moni cs gener ated i n
the magneti c ampl i fi ers (LI through
L4). I f these harmoni cs are not by-
passed, a sl i ght reducti on i n the out-
put gai n of the magneti c ampl i fi ers
may r esul t. Capaci tor s C22, C23,
C24, and C25 are used to suppress
th e s wi tch i n g tr a n s i en ts of CRI
through CR8.
c. Bal ance, Regulation, and Current Limit-
ing Circuits (S1 Set to CHARGE Position).
The bal ance and r egul ati on ci r cui ts ar e the
same as di scussed i n b above, except for r e-
moval of vari abl e resi stor R4 and di ode CR14
from the seri es ci rcui t of control wi ndi ng ter-
mi nal s 6 and 7. I nstead, vari abl e resi stor R3
and di ode CR9 are used i n the seri es ci rcui t
of contr ol wi ndi ng ter mi nal s 6 and 7. Wi th
no l oad appl i ed to the battery charger, di ode
CR9 i s bi ased to cutoff and no current fl ows
thr ough contr ol wi ndi ng ter mi nal s 6 and 7.
Wi th a l oad appl i ed to the batter y char ger ,
di ode CR9 i s for war d bi ased and cur r ent
fl ows thr ough contr ol wi ndi ng ter mi nal s 6
and 7. Thi s ci r cui t per mi ts output cur r ents
consi derabl y hi gher than 50 amperes for 28-
vol t operati on and 25 amperes for 56-vo1t op-
erati on (maxi mum current output wi th S1 set
to the NORMAL posi ti on). Wi th S1 set to
the CHARGE posi ti on, the maxi mum output
current can be as hi gh as 75 to 80 amperes
for 28-vol t operati on and 37.5 to 40 amperes
for 56-vol t operati on. Under thi s condi ti on,
the hi gh cur r ent fl owi ng thr ough contr ol
wi ndi ng termi nal s 6 and 7 wi l l i ncrease the
i mpedance of gate wi ndi ng ter mi nal s 1, 2,
and 3 and r esul t i n an output vol tage that
i s too l ow (appr oach 0 vol t) to be useful .
Capaci tor C12 bypasses the ac vol tage super-
i mposed on the dc vol tage and prevents the
ac vol tage from affecti ng regul ati on.
1-5
TM 11-6130-236-35
CHAPTER 2
TROUBLESHOOTING
Warning: When servicing the battery charger, be
extremely careful of the high voltages.
2-1. General Instructions
Troubl eshooti ng at the di rect support, general
support, and depot mai ntenance l evel i ncl udes al l
the techni ques outl i ned for organi zati onal mai n-
tenance and any speci al or addi ti onal techni ques
requi red to i sol ate a defecti ve part. Paragraph
2-4d provi des the troubl eshooti ng chart to be used
by the repai rman.
2-2. Organization of Troubleshooting
Procedures
a. General. The fi rst step i n servi ci ng a defecti ve
battery charger i s to l ocal i ze the faul t. Local i za-
ti on means traci ng the faul t to a defecti ve ci rcui t
responsi bl e for the abnormal condi ti on. The sec-
ond step i s i sol ati on. I sol ati on means the l ocati ng
of the defecti ve part or parts. Some defecti ve
parts, such as burned-out resi stors and arci ng
transformers, can oft i n be l ocated by si ght, smel l ,
or heari ng. Most defecti ve parts, however, must
be i sol ated by checki ng vol tages and resi stance.
b. Localization and I solation. The fi rst step i n
traci ng troubl e i s to l ocal i ze the defecti ve stage by
one of the fol l owi ng methods:
(1)
(2)
Visual inspection. The purpose of vi sual
i nspecti on i s to l ocate faul ts wi thout test-
i ng or measuri ng ci rcui ts. Al l meter i ndi -
cati ons or other vi sual si gns shoul d be
observed and an attempt made to l ocal i ze
the faul t to a parti cul ar part.
Voltage and resistance measurements. Use
the vol tage and resi stance val ues gi ven i n
paragraph 2-6 and compare them wi th
readi ngs taken.
(3)
(4)
(5)
Operational test. Operati onal test fre-
quentl y i ndi cate the general l ocati on of
troubl e. I n many i nstances, the test wi l l
hel p i n determi ni ng the exact nature of
the faul t. The dai l y preventi ve mai nte-
nance checks and ser vi ces char t (TM
11-6130-236-12) contai ns a good oper-
ati onal test.
Troubleshooting chart. The troubl eshoot-
i ng chart (para 24d) l i sts symptoms of
common troubl es and gi ves (or references)
correcti ve measures. Such a chart obvi -
ousl y cannot i ncl ude al l tr oubl e symp
toms that may occur . The r epai r man
shoul d use thi s chart as a gui de i n anal yz-
i ng symptoms that may not be l i sted.
Resistor and color code diagrams. Col or
code di agrams for resi stors and capaci tors
(fi gs. 4-1 and 4-2) provi de perti nent resi st-
ance, vol tage rati ng, and tol erance i nfor-
mati on.
2-3. Test Equipment Required
Note. Continue using the test equipment listed below until
new test equipment, listed in the latest Maintenance Alloca-
tion Chart (MAC) of TM 11-6130-236-12, becomes available.
a. Mul ti meter TS-352/U and Anal yzer ZM-3/U
ar e r equi r ed for tr oubl eshooti ng. Mul ti meter
TS-352/U i s used for conti nui ty tests, resi stance
measurements, and ac or dc vol tage measure-
ments. Anal yzer ZM-3/U i s used to test the
capaci tor s.
b. The fol l owi ng test equi pment and materi al s
are requi red to perform the adjustment proce-
dures gi ven i n paragraph 2-8:
(1) Mul ti meter ME-87/U (2 requi red), Feder-
al stock No. 6625-223-5248.
Change 1 2-1
TM 11-6130-236-35
(2)
(3)
(4)
(5)
(6)
Toggl e swi tch (2 requi red), Federal stock
No. 5930-823-2041.
Kni fe swi tch (2 requi red), Federal stock
No. 5930-224-4928.
Resi stance el ement, 0.58-ohm, 3,350-watt,
Federal stock No. 5905-280-0374.
Resi stance el ement, 0.86 ohm, 2,150-watt,
Federal stock No. 5905-185-8450.
Resi stance el ement, 1.36 ohm, 2,150-watt,
Federal stock No. 5905-186-8451.
24. Localizing Troubles
a. General. Procedures for l ocal i zi ng and i so-
l ati ng troubl es wi thi n the vari ous ci rcui ts of the
battery charger are gi ven i n the troubl eshooti ng
chart (d bel ow). Refer to fi gure 4-3 for component
l ocati ons. Refer to the schemati c di agram (fi g.
4-4) to i denti fy ci rcui t components. Vol tage and
resi stance measurements are gi ven i n paragraph
2-6. Dependi ng on the nature of the operati onal
symptoms, one or more of the l ocal i zi ng proce-
dures wi l l be necessary. When troubl e has been
l ocal i zed to a parti cul ar ci rcui t, use resi stance
and vol tage measurements to i sol ate the troubl e
to a parti cul ar part.
b. Use of Chart. The troubl eshooti ng chart i s
desi gned to suppl ement the operati onal checks
detai l ed i n TM 11-6130-236-12. I f previ ous oper-
ati onal checks have resul ted i n reference to a
parti cul ar i tem of thi s chart, go di rectl y to the
referenced i tem. I f no operati onal symptoms are
known, start wi th i tem 5 of the dai l y preventi ve
mai ntenance checks and ser vi ces char t (TM
11-6130-236-12) and pr oceed unti l a tr oubl e
symptom appears.
c. Conditions to Tests. Al l checks outl i ned i n
the troubl eshooti ng chart are to be conducted
wi th the battery charger connected to a power
source. Al ways remove i nput power before mak-
i ng any conti nui ty checks wi th ohmmeter.
d. Troubleshooting Chart.
Symptom
1. I ndi cator l amp DS1 does not
l i ght and fan motor B1 does
not start when power swi tch
and ci rcui t breaker CB1 i s
set to ON.
2. I ndi cator l amp DS1 l i ghts and
fan motor B1 does not opera-
ate.
3. Fan motor B1 operates and
i ndi cator l amp DS1 does not
l i ght.
4. I ndi cator l amp DS1 l i ghts but
no output vol tage i s present.
5. Errati c output wi th S1 i n
NORMAL posi ti on. Correct
output wi th S1 i n CHARGE
posi ti on.
Probabl e troubl e
DO ac power i s appl i ed to battery
charger.
Defecti ve CB1.
Defecti ve B1.
Power transformer T1 secondary
wi ndi ng termi nal s 9 and 10
open.
Defecti ve ful l -wave bri dge recti fi er
di odes CR1O through CR13.
Open i n output ci rcui t.
Defecti ve power transformer T1.
Defecti ve magneti c ampl i fi ers L1
through L4.
Defecti ve resi stor R4.
Defecti ve di ode CR14.
Correcti ve measures
Check for i nput vol tage.
Check CB1; repl ace i f defecti ve.
Repl ace B1.
Check for conti nui ty across termi -
nal s 9 and 10 of T1. Repl ace
T1 i f necessary.
Check CR1O through CR13. Re-
pl ace defecti ve di ode.
Check for l oose connecti ons,
broken l ead, or faul ty compon-
ent.
Repl ace power transformer T1.
Repl ace defecti ve magneti c ampl i f-
i er L1 through L4. (Defecti ve
magneti c ampl i fi ers must be re
pl aced i n matched pai rs. L1 and
L3 are one matched pai r. L2
and L4 are another matched
pai r .
Repl ace R4.
Repl ace CR14.
2 - 2
TM 11-6130-236-35
Symptom
Probabl e troubl e Correcti ve measure.
6. Errati c output output wi th S1 i n
CHARGE posi ti on. Correct
output wi th S1 i n NORMAL
posi ti on.
7. Batter y char ger cannot be
bal anced duri ng adjustment
procedure (para 28).
2-5. Tests for Open Fuses
a.. When to Check.
Defecti ve resi stor R3.
Defecti ve di ode CR9.
Defecti ve capaci tor C12.
Defecti ve vari abl e resi stor R1.
Defecti ve di ode CR15.
Defecti ve capaci tor C17.
Defecti ve VOLTAGE ADJUST re-
si stor R8.
Defecti ve vari abl e resi stor R2.
Defecti ve di ode CR14.
Defecti ve vari abl e resi stor R4.
Defecti ve wi ndi ng i n one of the
magneti c ampl i fi ers (L1, L2, L3,
or L4).
(1)
(2 )
Wh en a n y on e of fu s es F1 th r ou gh
F4 or F6 thr ough F9 opens conti nu-
ousl y wi th no l oad connected to the
batter y char ger or when ther e i s no
dc output fr om the batter y char ger .
Wh en fu s e F5 open s du r i n g oper a-
ti on (S1 i n NORMAL or
CHARGE posi ti on).
b. Conditions for Tests.
(1) Di s con n e ct the exter nal ] p o w e r
sour ces connected to r eceptacl e J 1.
(2) Di sconnect any l oad connected to the
DC OUTPUT ter mi nal s.
(3) Remove the cover s and panel s f o r
access to the components.
c. Tests. Mak e th e tes ts an d per for m th e
cor r ecti v e meas u r es i f fu s e F1, F2, F3, F4,
F6, F7, F8, or F9 i s open and the capaci tor
tested i s defecti ve.
Fuse Capaci tor to test Correcti ve measure.
F1
F2
F3
F4
F6
F7
F8
F9
C6
C7
C8
C13 and C14
C9
C10
C11
C15 and C16
Repl ace C6.
Repl ace C7.
Repl ace C8.
Repl ace C13 and/or C14.
Repl ace C9.
Repl ace C10.
Repl ace C1l .
Repl ace C15 or C16.
Repl ace R3.
Repl ace CR9.
Repl ace C12.
Check R1 and repl ace i f necessary.
Repl ace CR15.
Repl ace C17.
Check R8 and repl ace i f necessary.
Check R2 and repl ace i f necessary.
Repl ace CR14.
Check R4 and repl ace i f necessary.
Check wi ndi ng of L1, L2, L3, and
L4 (para 2-6) and repl ace i f
necessary. (Defecti ve magneti c
ampl i fi ers must be repl aced i n
matched pai rs. (L1 and L3
are one matched pai r. L2 and
L4 are the other matched pai r).
d. Additional Tests. I f fuse F5 i s open,
proceed as fol l ows:
(1)
(2)
(3)
Test capaci tor C17 and r epl ace i f
defecti ve.
Test Zener di ode CR15 and r epl ace
i f defecti ve.
Caution: Magnetic amplifiers must
be repl aced i n matched pai rs. Mag-
netic amplifiers L1 and L3 are one
matched pair; magnetic amplifiers L2
and L4 are the other matched pair.
Test magneti c ampl i fi ers L1, L2, L3,
and L4 (para 26). I f a magneti c
ampl i fi er i s defecti ve, repl ace t h e
defecti ve magneti c ampl i fi er.
2-6. Additional Troubleshooting Data
a. Voltage Output of Power Transformer
T1. The vol tage output data of power trans-
former T1 are provi ded as an ai d to troubl e-
s h ooti n g. Th e v ol ta ges of T1 s econ d a r y
wi ndi ngs are l i sted bel ow:
Secondary winding terminals Ac voltage indication
( approx)
5-6 42
78 42
9-10 30
b. Dc Resistances of Transformer, Filter
Chokes, Relays, and Magnetic Amplifiers. Th e
dc resi stance data ( (3) bel ow) are provi ded
2-3
TM 11-6130-236-35
as an ai d to troubl eshooti ng. When usi ng the
data, observe the fol l owi ng precauti ons:
Caution: Do not measure resi stance when
i nput power i s appl i ed to the battery charger
and when the power swi tch and ci rcui t break-
er i s at ON. Di sconnect the power pl ug and
pl ace the power swi tch and ci rcui t breaker to
OFF.
(1)
(2)
(3)
Befor e maki ng r esi stance measur e-
ments, determi ne whether faul ty op-
erati on i s caused by a faul ty trans-
former, fi l ter choke, rel ay or magne-
ti c ampl i fi er. To do thi s, fol l ow the
tr oubl eshooti ng pr ocedur es as out-
l i ned i n paragraph 24d
Do not use the resi stance measure-
ments as the sol e basi s to determi ne
that a transformer, fi l ter choke, re-
l ay, or magneti c ampl i fi er i s defec-
ti ve. Resi stances may vary from one
tr ansfor mer , fi l ter choke, r el ay, or
magneti c ampl i fi er to another , be-
cause of br oad wi ndi ng tol er ances
dur i ng manufactur e. The val ues
gi ven i n the char t ( (3) bel ow) ar e
typi cal average val ues.
Dc resi stances of transformed, fi l ter
chokes, rel ays, and magneti c ampl i -
fi ers are as fol l ows:
Transformer, fi l ter
chokes, and rel ays
I
Ter mi nal s
I
Resi stance (ohms}
T1
l -2
Less than 1
3-4 Less than 1
5-6 Less than 1
7-8 Less than 1
910 Less than 1
3-4 Less than 1
L5A 1-2 Less than 1
K1 X1-X2 110
K2 X1-X2 110
L1, L2, L3, 1-2 Less than 1
and L4 2-3 Less than 1
45 37
6-7 3
27. General Parts Replacement
Techniques
The battery charger parts can be reached
and repl aced wi thout speci al procedures. Refer
to fi gure 43 for the l ocati on of parts. When
2-4
sol der i ng connecti ons to the di odes,
sol der
qui ckl y; use a heat si nk (such as l ong-nosed
pl i er s) between the sol der ed joi nt and the
di ode.
2-8. Adjustment of Variable Resistors
R1, R2, R3, and R4
(fig. 2-1)
Caution: Be sure the battery charger is
connected as specified in paragraph 2-3, TM
11-6130-236-12.
Per for m the pr ocedur es gi ven bel ow after
major repai r of the battery charger or when
the i nput power source to be used i s
changed fr om 50/60 to 400 cps; or f r om
400 to 50/60 cps.
a. Resistors R1 and R2, Magnetic Ampli-
fiers Current Balance Adjustment.
(1)
(2)
(3)
(4)
Remove both of the 28 DC OUT-
PUT 56 l i nks and connect the nega-
ti ve ter mi nal s of each of Mul ti me-
ter s ME87/U (ammeter ) connected
as ammeters to each of the termi nal s
marked 28.
Connect the posi ti ve ter mi nal s of
each of the ammeters to each of the
associ ated unmar ked ter mi nal s a s
shown i n fi gure 21.
Remov e th e s h or ti n g l i n k s fr om
TB1 and TB2.
Connect toggl e swi tches to TB1 and
TB2 as fol l ows:
(a.)
(b)
(c)
(d)
The center termi nal of one toggl e
swi tch to ter mi nal 2 of TB1 and
the center ter mi nal of the other
toggl e s wi tch to ter mi n al 2 of
TB2.
Ter mi n al 1 on TB1 to th e l eft
termi nal of the toggl e swi tch con-
nected to TB1 and termi nal 1 on
TB2 to the l eft ter mi nal of the
toggl e swi tch connected to TB2.
Ter mi nal 3 on TB1 to the r i ght
termi nal of the toggl e swi tch con-
nected to TB1 and termi nal 3 on
TB2 to the r i ght ter mi nal of the
toggl e swi tch connected to TB2.
Set both toggl e swi tches to open
posi ti on.
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Set the NORMAL-CHARGE swi tch
to NORMAL, the 28V-S2-56V
swi tch to 28V, and the VOLTAGE
ADJUST contr ol ful l y counter cl ock-
wi se.
Connect the 1/4-l oad resi stors (1.36-
ohm i n ser i es wi th 0.86-ohm, total
2.22-ohms resi stance) i n seri es wi th
one kni fe swi tch and the ful l -l oad
r esi stor (0.58-ohm) i n ser i es wi th
th e oth er k n i fe s wi tch to th e +
OUTPUT - ter mi nal s as shown i n
fi gure 21. Set both kni fe swi tches
to open posi ti on.
Set the power swi tch and ci r cui t
br eaker to ON. After a 2-mi nute
war mup, appl y one-quar ter l oad by
cl osi ng the k ni fe swi tch i n ser i es
wi th the one-quarter l oad.
Rotate th e VOL TAGE ADJUST
control for an i ndi cati on of 28 vol ts
on the OUTPUT VOLTAGE meter.
Set the toggl e swi tch connected t o
TB2 to i ts l eft pos i ti on . Obs er v e
and note the i ndi cati on on each am-
meter . Set the same toggl e swi tch
to i ts r i ght posi ti on. Obser ve and
note the i ndi cati on on each ammeter.
Set the toggl e swi tch i n the posi -
ti on (l eft or ri ght) that provi des the
mi ni mum current di fference between
the two ammeter s. (For exampl e,
wi th the toggl e swi tch set to the
l eft, one ammeter i ndi cates 4 am-
per es and the other ammeter i ndi -
cates 8 amperes. Wi th t h e toggl e
swi tch set to the ri ght, one ammeter
i ndi cates 5 amper es and the other
ammeter i ndi cates 7 amperes. F o r
thi s condi ti on, the toggl e swi tch i s
set to the ri ght.) Adjust vari abl e re
si ster R2 unti l the ammeters i ndi cate
the l owest val ue of i mbal ance.
Remove the one-quarter l oad by set-
ti ng the seri es-connected swi tch t o
the open posi ti on. Appl y ful l -l oad
by cl osi ng the swi tch i n seri es wi th
the ful l -l oad.
Readjust R2 as necessar y unti l the
ammeter s i ndi cate the l owest val ue
of i mbal ance. The greatest tol erabl e
(13)
(14)
(15)
(16)
(17)
TM 11-6130-236-35
val ue of i mbal ance i s 5 amper es of
di ffer ence between both ammeter s
wi th a ful l l oad appl i ed. Repai r of
the battery charger i s requi red i f an
i mbal ance greater than 5 amperes ex-
i sts after adjusti ng R2.
Remov e th e fu l l l oad by s etti n g
the seri es connected kni fe swi tch to
open posi ti on.
Set the toggl e swi tch connected to
TB1 to i ts l eft pos i ti on . Obs er v e
and note the i ndi cati on on each am-
meter . Set the same toggl e swi tch
to i ts ri ght posi ti on. Observe a n d
note the i ndi cati on on each ammeter.
Set the toggl e swi tch i n the posi ti on
(l eft or r i gh t) th at pr ov i des th e
mi ni mum current di fference between
the two ammeters. Adjust var i abl e
resi stor R1 unti l each ammeter i ndi -
cates 0 current.
Set the pcwer swi tch and ci r cui t
breaker to OFF.
Di sconnect each toggl e swi tch and
repl ace the shorti ng l i nks across the
termi nal s of TB1 and TB2 that were
shor ted by the toggl e swi tches for
the adjustment of R1 ( (15) above)
and R2 (10) above).
b. Resistor R4 Regulation Adjustment. Af -
ter per for mi ng the magneti c ampl i fi er s cur -
rent bal ance adjustment (a above), adjust var-
i abl e resi stor R4 as fol l ows:
(1)
(2)
(3)
(4)
(5)
Set the power swi tch and ci r cui t
br eak er to ON. Rotate the VOLT-
AGE ADJUST contr ol for an i ndi -
cati on of 28 vol ts on the OUTPUT
VOLTAGE meter.
Appl y a fu l l l oad by cl os i n g th e
kni fe swi tch i n ser i es wi th the ful l
l oad. Adjust vari abl e resi stor R4 for
an i ndi cati on between 27.7 vol ts and
27.9 vol ts on the OUTPUT VOLT-
AGE meter.
Readjust R2 as necessar y for mi ni -
mum i mbal ance (a ( 12) above).
Remove the ful l l oad by setti ng the
seri es-connected
open posi ti on.
Set the power
breaker to OFF.
kni fe swi tch to the
swi tch and ci r cui t
2-5
TM 11-6130-236-35
(6)
(7)
(8)
Remove both ammeters from the 28
DC OUTPUT 56 termi nal s. Repl ace
both of th e 28 DC OU TPU T 56
l i nks for 28-vol t output power.
Appl y a fu l l l oad by cl os i n g th e
kni fe swi tch i n ser i es wi th the ful l
l oad. I f necessar y, r eadjust R4 for
an i ndi cati on between 27.7 vol ts and
27.9 vol ts on the OUTPUT VOLT-
AGE meter.
Set the power swi tch and c i r c u i t
breaker to OFF.
c.Resi stor R3 Maxi mum Current for
CHARGE Mode Adjustment.
(1)
(2)
(3)
Remove the one-quar ter l oad, ful l
l oad, both kni fe swi tches, and hook-
up wi re from the + OUTPUT ter-
mi nal s.
Rotate v ar i abl e r es i s tor R3 fu l l y
countercl ockwi se.
Connect one end of a 10-foot No. 8
AWG wi r e to the + OUTPUT ter -
mi nal and the other end of the No.
8 AWG wi r e to the - OUTPUT ter -
mi nal . (The 10-foot l ength of No.
8 AWG wi r e acr oss the + OUTPUT
termi nal s i s used to si mul ate t h e
requi red short ci rcui t to adjust R3.)
(4) Set the NORMAL-CHARGE swi tch
to CHARGE.
Caution: The procedure, gi ven i n
(5) bel ow i s for CHARGE mode of
oper ati on onl y. Be sur e that the
NORMAL-CHARGE swi tch i s i n the
CHARGE posi ti on before appl yi ng i n-
put power to the battery charger.
(5)
(6)
(7)
(8)
(9)
Set the power swi tch and ci r cui t
br eak er to ON. (Th e OU TP U T
CURRENT meter s h ou l d i n di cate
between 40 amper es an d 50 am-
peres.)
Adjust var i abl e r esi stor R3 for an
i ndi cati on of between 70 amper es
and 75 amper es on th e OUTPUT
CURRENT meter.
Set the power swi tch and ci r cui t
breaker to OFF.
Set the NORMAL-CHARGE swi tch
to NORMAL.
Remove the No. 8 AWG wi r e fr om
the + OUTPUT termi nal s.
2-6
Fi gure 2-1. Adj ustment of vari abl e resi stor R1, R2, R3, and R4 connecti on di agram.
2 - 7
TM 11-6130-236-35
CHAPTER 3
GENERAL SUPPORT TESTING PROCEDURES
3-1. General
a. Testi ng procedures are prepared for use by
Si gnal Fi el d Mai ntenance Shops and Si gnal Serv-
i ce Organi zati ons responsi bl e for general support
mai ntenance of el ectroni c equi pment to deter-
mi ne the acceptabi l i ty of repai red equi pment.
These procedures set forth speci fi c requi rements
that repai red equi pment must meet before i t i s
returned to the usi ng organi zati on. These proce-
dures may al so be used as a gui de for testi ng
equi pment whi ch has been repai red at di rect
support l evel i f the proper tool s and test equi p-
ment are avai l abl e. A summary of the perform-
ance standards i s gi ven i n paragraph 3-8.
b. Compl y wi th the i nstructi ons precedi ng each
chart before proceedi ng to the chart. Perform
each step i n sequence. Do not vary the sequence.
For each step, perform al l the acti ons requi red i n
the Control settings col umn; then perform each
speci fi c test procedure and veri fy i t agai nst i ts
performance standard.
3-2. Test Equipment, Tools, and
Materials
Al l test equi pment, tool s, and materi al s re-
qui red to perform the testi ng procedures gi ven i n
thi s chapter are l i sted i n a, b, and c, bel ow and are
authori zed under TA 11-17, (Si gnal Fi el d Mai nte-
nance Shops); and TA 11-100 (1117), (Al l owances
of Si gnal Corps expendabl e Suppl i es for Si gnal
Fi el d Mai ntenance Shops).
Note. Conti nue usi ng the test equi pment l i sted bel ow unti l
new test equi pment, l i sted i n the l atest Mai ntenance Al l oca-
ti on Chart (MAC) of TM 11-6130-236-12, becomes avai l abl e.
Change 1 3-1
TM 11-6130-236-35
a. Test Equipment.
Nomenclature
Multimeter TS-352/U (2 required)
Wattmet.er TS-430/U
Transformer, Variable Power
TF-171A/U
Voltmeter, Meter ME30A/U
Low Voltage Circuit Tester
TV-loo
Federal stock No.
6625-242-5023
6625-649-5393
5950-503-0632
6625-669-0742
4910-092-9136
b. Tools. All the tools required are included in
Tool Kit, Radio and Radar Repairman TK-87/U.
c. Materials.
Nomenclature
Wire, electrical, stranded;
#10 AWG
Resistance Element,
0.58-ohm, 3,350-watt
(load for 28-volt
tests)
Federal stock No.
6145-160-5110
5905-280-0374
Technical manual
TM 11-5527
None
None
TM 11-6625-320-12
None
Nomenclature
Resistance Element,
1.36-ohm, 2,150-watt
(part of bad for
56-volt tests)
Resistance Element,
0.86+hm, 2,150-watt
(part of load for 56-
Volt tests)
Knife switch (60-ampere)
Federal stock No.
5905-186-8451
5905-186-8450
5930-224-4928
3- 2 Change 1
TM 11-6130-236-35
33. Physical Tests and Inspections
b. Test Connections and Conditions. NO
connecti ons necessary. Remove panel s a n d
a. Test Equipment and Materials. None covers as necessary for vi sual and actual ac-
r equi r ed.
eess to al l components.
c. Procedures.
Step
No.
1
2
3
Control setti ngs
I est equi pment Equi pment under
test
None
None
None
Control s may be
i n any posi ti on,
Control s may be
i n any posi ti on.
Control s may be
i n any posi ti on.
Test procdure
a. I nspect case and chassi s for
damage, mi ssi ng parts, and
condi ti on of pai nt.
Note. Touchup pai nti ng i s
recommended i n l i eu of refi n-
i shi ng whenever practi cal ; screw-
heads, bi ndi ng posts, receptacl es,
and other pl ated parts wi l l not be
pai nted or pol i shed wi th abrasi ves.
b. I nspect al l control s and mechan-
i cal assembl i es for l oose or
mi ssi ng screws, bol ts, and
nuts.
c. I nspect al l connectors, recepta-
cl es, meters, and fusehol ders
for l ooseness, damage, or
mi ssi ng parts.
a. Rotate al l panel control s
through thei r l i mi ts of travel .
b. Operate al l swi tches.
Manual l y turn fan bl ades of
motor B1.
Performance standard
a. No damage evi dent or parts
mi ssi ng. External surfaces i n-
tended to be pai nted do not
show bare metal . Panel
l etteri ng wi l l be l egi bl e.
b. Screws, bol ts, and nuts are
ti ght. None mi ssi ng.
c. No l oose parts or damage,
mi ssi ng parts.
No
a. Contr ol s r otate fr eel y wi thout
bi ndi ng or excessi ve l oose-
ness.
b. Swi tches operate properl y.
Fan bl ades turn freel y wi thout
bi ndi ng.
3-3
TM 11-6130-236-35
Figure 3-1. Twenty-eight Volt output, regulation, ripple, and efficiency test
connection diagram.
3-4
CHAPTER 4
DEPOT OVERHAUL STANDARDS
4-1. Applicability of Depot Overhaul
Standards
The tests outl i ned i n thi s chapter are desi gned
to measure the performance capabi l i ty of a re-
pai red equi pment. Equi pment that i s to be re-
turned to stock shoul d meet the standards gi ven
i n these tests.
4-2. Applicable References
a. Repair Standards. Appl i cabl e procedures of
the depots performi ng these tests and the general
standar ds for r epai r ed el ectr oni c equi pment
gi ve i n TB SI G 355-1, TB SI G 355-2, and TB SI G
355-3 form a part of the test requi rements.
b. Technical Publication. The techni cal publ i -
cati on appl i cabl e to the equi pment to be tested i s
TM 11-6130-236-12.
c. Modification Work Orders. Perform al l modi -
fi cati on work orders appl i cabl e to thi s equi pment
before maki ng the tests speci fi ed. DA Pam 310-4
l i sts al l avai l abl e MWOs.
4-3. Test Facilities Required
The fol l owi ng i tems are requi red for depot
testi ng:
a. Test Equipment.
Note. Continuing using the test equipment listed below until new test equipment, listed in the latest Maintenance
Allocation Chart (MAC) of TM 11-6130-236-12, becomes available.
Item
Multimeter TS-352/U (2 required)
Wattmeter TS-430/U
Transformer, Variable Power
TF-171A/U
Voltmeter, Meter ME-30A/U
Low Voltage Circuit Tester
TV-l00
b. Materials
Federal stock No. Technical manual
6625-242-5023 TM 11-5527
6625-649-5393 None
5950-503-0632 None
6625-669-0742 TM 11-6625-320-12
4910-092-9136 None
Nomencl ature
Wi re, el ectri cal stranded;
#10 AWG
Resi stance El ement, 0.53-
ohm, 3,350-watt (l oad
for 23-vol t tests)
Resi stance El ement, 1.36-
ohm, 2,150-watt (part of
l oad for 56-vol t tests)
Resi stance El ement, 0.36
Federal stock No.
6145-160-5110
5905-280-0374
5905-186-3451
5905-136-3450
Nomencl ature Federal duck No.
ohm, 2,150-watt (part of
l oad for 56 vote tests)
Kni fe swi tch (60 ampere) 5930-224-4928
4-4 Tests
The depot overhaul standards test procedures
are the same as those for general support (para
3-4 through 3-7). Equi pment that meets the per-
formance standards stated i n these tests wi l l
furni sh sati sfactory operati on equi val ent to that
of new equi pment.
Change 1 4-1
TM 11-6130-236-35
COLOR CODE MARKING FOR MILITARY STANDARD RESISTORS
*I f B and D is omitted, the resistor tolerance is .+. 20%, and the resistor is not Mil-Std.
Figure 41. Color code marking for MI L STD resistors.
4 - 2
TM 11-6130-236-35
APPENDIX
REFERENCES
DA Pam 310-4
TA 11-17
TA 11-100 (11-17)
TM 11-487H-1/1
TM 11-5043-12
TM 11-5527
TM 116130-236-12
TM 11-6130-236-25P
TM 116625320-12
I ndex of Techni cal Manual s, Techni cal Bul l eti ns, Suppl y Manual s (types
7, 8, and 9), Suppl y Bul l eti ns, Lubri cati on Orders, and Modi fi cati on
Work Orders.
Si gnal Fi el d Mai ntenance Shops.
Al l owances of Si gnal Corps Expendabl e Suppl i es for Si gnal Fi el d Mai n-
tenance Shops.
El ectroni c Test Equi pment.
Operators and Organi zati onal Mai ntenance Manual : Anal yzers ZM3/U
and ZM3A/U.
Mul ti meters TS-352/U, TS-352A/U, and TS352B/U.
organi zati onal Mai ntenance Manual : Charger, Battery PP1451/G.
organi zati onal , DS, GS, and Depot Mai ntenance Repai r Parts and Speci al
Tool Li sts: Charger, Battery PP-1451/G.
organi zati onal Mai ntenance Manual : Vol tmeter, Meter ME30A/U and
Vol tmeter s, El ectr oni c ME30B/U, ME30C/U, and ME30E/U.
A-1
By Order of the Secretary of the Army:
Offi ci al :
J. C. LAMBERT,
Major General, United States Army,
The Adjutant Genenal.
Di stri buti on:
Acti ve Army:
USASA (2)
CNGB (1)
CC-E (7)
Di r of Tram (1)
CofEngrs (1)
TSG (1)
CofSptS (1)
USAAESWBD (5)
USAAVNTBD (5)
USACDCEA (1)
USACDCCBRA (1)
USACDCCEA (1)
USACDCCEA:
Ft Huachuca (1)
USACDCOA (1)
USACDCQMA (1)
USACDCTA (1)
USACDCADA (1)
USACDCARMA (1)
USACDCAVNA (1)
USACDCARYTA (1)
USACDCSWA (1)
USAMC (5)
USCONARC (5)
ARADCOM (5)
ARADCOM Rgn (2)
OS Maj Comd (4)
LOGCOMD (2)
USAMI COM (4)
USASMC (2)
USASCC (4)
MDW (1)
Armi es (2)
Corps (2)
USAC (3)
507th USASA Gp (2)
508th USASA Gp (2)
318th USASA Bn (2)
319th USASA Bn (2)
NG: State AG (3).
320th USASA Bn (2)
177th USASA Co (2)
182nd USASA Co (2)
183rd USASA Co (2)
184th USASA Co (2)
251st USASA Co (2)
102nd USASA Det (2)
104th USASA Det (2)
Svc Col l eges (2)
Br Svc Sch (2) except
USATSCH (5)
USA Tng Cen & Sch (5)
Si g FLDMS (2)
AMS (1)
USMA (5)
GENDEP (2)
Si g Sec GENDEP (5)
Si g Dep (12)
A Dep (2) except
LBAD (14)
SAAD (30)
TOAD (14)
FTWOAD (10)
LEAD (7)
SHAD (3)
NAAD (5)
SVAD (5)
CHAD (3)
ATAD (10)
SEAD (7)
USASTC (2)
USATC Armor (2)
USATC Engr @)
USATC I nf (2)
Army Pi c Cen (2)
USACDCEC (10)
USATTC (5)
USAJFKCENSPWAR (5)
I nstl (2) except
USAR: None.
For expl anati on of abbrevi ati ons used, see AR 320-50.
HAROLD K. JOHNSON,
General, United States Army.
Chief of Staff.
Ft Monmouth (70)
Ft Hancock (4)
Ft Gordon (10)
Ft Huachuca (10)
Ft Carson (21)
Ft Knox (12)
Ft Ri tchi e (5)
WSMR (5)
WRAMC (1)
USAERDAA (2)
USAERDAW (13)
USACRREL (2)
USARSG (5)
Uni ts org under fol TOE:
(2 copi es each)
11-6
11-35
11-37
1138
11-39
1156
1157
11-97
11-98
11117
11155
11156
11157
11158
11225
11226
11358
11-500 (AA-AC)
11-587
11592
11597
2956
29134
*U.S. GOVERNMENT: PRINTING OFFICE : 1989 0 - 242-451 (6027)Text
P I N : 0 2 0 6 6 8 - 0 0 0