TM 11-6130-227-45DEPARTMENT OF THE ARMY TECHNICAL MANUAL

FIELD (FOURTH ECHELON) AND DEPOTMAINTENANCE MANUAL

CHARGER, BATTERY PP-1660/G

Headquarters, Department of the Army, Washington 25, D.C.

29 June 1962

1.

2.

WARNING

HIGH VOLTAGE

is used in this equipment.

DEATH ON CONTACT

may result if safety precautionsare not observed.

Be careful when working on the 115-volt ac input circuit.Use insulated test probes when making voltage measure-ments. When working inside the equipment, be extremelycareful not to touch any internal parts while the batterycharger is energized. Disconnect the ac input cable be-fore performing routine maintenance or attempting toremove any part.

The failure of selenium rectifiers can result in the liber-ation of poisonous fumes and the deposit of poisonousselenium compounds. When a rectifier burns out or arcsover, the odor is strong. Provide maximum ventilationimmediately. Avoid inhaling the fumes. Do not touch thedamaged rectifier until it has cooled.

DON’T TAKE CHANCES!

Paragraph PageCHAPTER 1. INTRODUCTION

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2Associated publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 2

C H A P T E R 2 . THEORYBlock diagram analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3Circuit analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3

1THIS PUBLICATION IS A COURTESY QUICK COPYFROM THE UNITED STATES ARMY PUBLICATIONSDISTRIBUTION CENTER, ST. LOUIS, MISSOURI,TO MEET YOUR NEEDS WHILE WE REPLENISH OURREGULAR STOCK.

C H A P T E R 3 . MAINTENANCE INSTRUCTIONS Paragraph

Section I. GeneralScope of field and depot maintenance . . . . . . . . . . . . . . . . . . . . . . .Tools, materials, and test equipment . . . . . . . . . . . . . . . . . . . . . . .

II. Routine maintenanceScope of routine maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . .Routine maintenance procedures . . . . . . . . . . . . . . . . . . . . . . . . . .

III. TroubleshootingScope of troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Voltage measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Resistance measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IV. Removal and replacement of parts and testing after repairGeneral procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal and replacement of parts . . . . . . . . . . . . . . . . . . . . . . . . .Testing after repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C H A P T E R 4 . FINAL TESTINGPurpose of final testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Test equipment for final testing . . . . . . . . . . . . . . . . . . . . . . . . . .Physical inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Insulation resistance tests . . . . . . . . . . . . . . . . . . . . . . . . . . .Function tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56

78

910111213

141516

1718192021

7

77

889

1011

111113

1616161617

APPENDIX. REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

CHAPTER 1

INTRODUCTION

1. Scopea. This manual covers field (fourth ech-

elon) and depot (fifth echelon) maintenanceof Charger, Battery PP-1660/G. It in-cludes instructions appropriate to fourthand fifth echelons for routine maintenanceof the PP-1660/G; for troubleshooting,testing, and repairing this equipment, andfor replacing maintenance parts. Theelectrical functions of the equipment aredescribed in paragraphs 3 and 4.

b. Refer to DA Pamphlet No. 310-4 todetermine what Changes to or revisionsof this publication are current.

c. Forward all comments concerningthis manual to the Commanding Officer,

U. S. Army Signal Materiel SupportAgency, ATTN: SIGMS-MPP-4, Fort Mon-mouth, N. J.

Note: For applicable forms and records, see par-agraph 2, TM 11-6130-227-12.

2. Associated Publications

The operating instructions and oper-ator’s (first echelon) and organizational(second echelon) maintenance instructionsFor the PP-1660/G are contained in TM11-6130-227-12. TM 11-6130-227-12 alsocontains the basic issue items list andcovers maintenance allocation for thisequipment.

2

CHAPTER 2

THEORY

3. Block Diagram Analysis(fig. 1)

During fast charging, the contacts ofTIME SWITCH M1 are closed and the al-ternating-current (ac) input is applieddirectly to the primary winding of trans-former T1. During slow charging, thecontacts of TIME SWITCH M1 are open andthe 115-volt ac input is connected throughcurrent-limiting reactor L1 to the pri-mary winding of transformer T1. Trans-former T1 has two separate secondarywindings. The output of one is connectedto rectifier CR1, and the output of the otheris connected to rectifier CR2. The full-wave direct-current (dc) outputs of rec-tifiers CR1 and CR2 are switched by re-lays K2 through K6 into series or parallelcombinations to provide the proper dcoutput voltages and currents for fast-or slow-charging 6-, 12-, or 24-voltstorage batteries.

4. Circuit Analysis(fig. 2)

a. Ac Input Circuit. One side of the 105-to 125-volt ac input is connected, by meansof plug connector P1 and the ac inputcable, through either TIME SWITCH M1or reactor L1 to CHARGE SWITCH S1; theother side of the ac input is connectedto terminal 5 of transformer T1. TIMESWITCH M1 is a mechanically operatedclock with a normally open electricalcontact.

(1) When TIME SWITCH M1 is in theSLOW CHARGE position, its elec-trical contact is open. The ac inputthen is connected through reactorL1 and circuit breaker CB1 to therotor of CHARGE SWITCH S1, andthe ac input circuit is completedthrough the selected contact ofCHARGE SWITCH S1 and the asso-ciated tap of the primary windingof transformer T1 (b below). Reac-

(2)

tor L1 is a choke that limits theinput current applied to trans-former T1. Circuit breaker CB1 isa thermal type, automatic resetcircuit breaker rated at 5 amperes.Connected in series with reactorL1, it opens the input circuit toprotect reactor L1 from overloadwhen the input current exceedsthis value. After a cooling period,circuit breaker CB1 recloses theinput circuit automatically.Setting TIME SWITCH M1 to anytime interval between 1 and 55minutes closes its electrical con-tact and winds the clock mechan-ism, which holds the contact closeduntil the expiration of the time in-terval for which TIME SWITCH M1is set. When the contact of TIMESWITCH M1 is closed, the ac inputis connected, directly to the rotorof CHARGE SWITCH S1 and the in-put circuit is completed through these lec ted contac t of CHARGESWITCH S1 and the associated tapof the primary winding of trans-former T1 (b below).

b. Transformer T1 Circuits. T r a n s -former T1 has a multiple-tapped primarywinding and two separate, identical,center-tapped secondary windings. Pri-mary tapes 1, 2, 3, and 4 are connectedto contacts 3, 4, 5, and 6, respectively,of CHARGE SWITCH S1. Thus the settingof CHARGE SWITCH S1 determines thenumber of effective turns of the primarywinding of transformer T1 and conse-quently the voltage and current of the out-puts of the two secondary windings. Thisarrangement provides a range of trans-former outputs that permits the selectionof a high, medium, or low charging rate(c below). Blower motor B1 is connectedacross the ac input between contact 5 ofCHARGE SWITCH S1 and terminal 5 of theprimary winding of transformer T1. The

3

TM 6130-227-45-1

Figure 1. Charger, Battery PP-1660/G, block diagram.

primary winding of transformer T1 actsas an autotransformer so that the voltageapplied to blower motor B1 increases asCHARGE SWITCH S1 is advanced fromLOW to MED to HIGH and consequentlythe speed of blower motor B1 incresaesproportionally. Thus, a larger amount ofcooling air is drawn in and expelled by theblower as the charging rate is increased.

c. Rectifier Circuits. Transformer T1has two separate, identical secondarywindings whose output voltage is controlledby the position of CHARGE SWITCH S1(b above). The output of secondary winding6-8 is connected to rectifier CR1, and theoutput of secondary winding 9-11 is con-nectad to rectifier CR2. Each rectifier isa full-wave, bridge rectifier; this arrange-ment provides two separate full-wave rec-tifier circuits. Each rectifier circuit hasa maximum output of approximately 12.6volts at 40 amperes. These outputs areconnected to five solenoid relays (K2through K6) in such a manner that theycan be switched into series and parallelcombinations (d below) to provide properdc voltages and currents for fast- orslow-charging 6-, 12-, or 24-volt storagebatteries. Circuit breakers CB2 and CB3are connected into the output circuits ofrectifiers CR1 and CR2, respectively,to protect the rectifiers from overloadwhen the battery charger is operated inthe fast-charge range. Circuit breakersCB2 and CB3 are thermal type, automaticreset circuit breakers. Each is rated at40 amperes and will open its rectifiercircuit when the dc output current of that

4

circuit exceeds this value. After a coolingperiod, the circuit breaker will reclosethe rectifier circuit automatically. Am-meter M2 is a dc ammeter inserted in oneside of the dc output circuit. It indicatesthe dc output of the battery charger (charg-ing rate) in amperes. Resistor R1 is ameter shunt for ammeter M2.

d. Switching Circuits. The switchingcircuits consist of BATTERY VOLTSswitch S2 and solenoid relays K2 throughK6, which are energized in various com-binations, depending on the position ofBATTERY VOLTS switch S2. The 6-voltdc required to energize the coils of therelays is taken from legs B and C of rec-tifier CR2.

(1) 6-volt charging. When BATTERYVOLTS switch S2 is in the 6 posi-tion, relays K2 and K6 are ener-gized. The energizing circuit isfrom center tap 10 of winding 9-11of transformer T1, through BAT-TERY VOLTS switch S2 in the 6position, through the coils of relaysK2 and K6 in parallel, through nor-mally closed contacts 3-4 of relayK1, to the negative (-) terminalof rectifier CR2. When relays K2and K6 are operated, two parallelcircuits, using legs B and C ofrectifier CR1 and legs A and D ofrectifier CR2 as a full-wave, cen-ter-tap rectifier, are established.This arrangement produces a dcoutput of approximately 6.5 voltsat 75 amperes maximum. Onecircuit is from center tap 7 of

winding 6-8 of transformer T1,through contacts 4-3 of relay K6,through ammeter M2 to positive(+) battery connector P3, throughthe battery under charge to nega-tive (-) battery connector P2, andthrough circuit breaker CB2 to thenegative terminal of rectifier CR1.The other circuit is from the posi-tive (+) terminal of rectifier CR2,through circuit breaker CB3 andammeter M2 to positive batteryconnector P3, through the batteryunder charge to negative batteryconnector P2, through contacts 4-3of relay K2, to center tap 10 ofwinding 9-11 of transformer T1.The coil of relay K1 is connecteddirectly across the dc output of therectifiers and controls the opera-tion of relays K2 and K6. RelayK1 will operate (open its contacts)when a voltage of 16 to 18 voltspasses through its coil. This de-energizes relays K2 and K6 andopens the dc output circuit to pre-vent damage to the rectifiers incase of overload.

(2) 12-volt charging. When BATTERYVOLTS switch S2 is in the 12position, relays K3 and K5 are en-ergized. The energizing circuit isfrom center tap 10 of winding 9-11of transformer T1, through BAT-TERY VOLTS switch S2 in the 12position, through the coils of re-lays K3 and K5 in parallel, to thenegative terminal of rectifier CR2.When relays K3 and K5 are oper-ated, two full-wave rectifer cir-cuits, using rectifiers CR1 andCR2 connected in parallel, areestablished. This arrangementproduces a dc output of approxi-mately 12.6 volts at 75 amperes maximum. One circuit is from the

positive terminal of rectifier CR2,through circuit breaker CB3 andammeter M2 to positive batteryconnector P3, through the batteryunder charge to negative batteryconnector P2, through contacts 3-4of relay K3 to the negative terminalof rectifier CR2. The other circuitis from the positive terminal ofrectifier CR1, through contacts3-4 of relay K5 and ammeter M2to positive battery connector P3,through the battery under chargeto negative battery connector P2,and through circuit breaker CB2to the negative terminal of rec-tifier CR1.

(3) 24-volt charging. When BATTERYVOLTS switch S2 is in the 24position, relay K4 is energized.The energizing circuit is fromcenter tap 10 of winding 9-11 oftransformer T1, through BAT-TERY VOLTS switch S2 in the 24position, through the coil of relayK4, to the negative terminal of rec-tifier CR2. When relay K4 is op-erated, a full-wave rectifier cir-cuit, using rectifiers CR1 and CR2connected in series, is established.This arrangement provides a dcoutput of approximately 26 voltsat 40 amperes maximum. Thiscircuit is from the positive termin-al of rectifer CR1, through con-tacts 4-3 of relay K4 to the negativeterminal of rectifer CR2, throughrectifier CR2 to its positive termi-nal, through circuit breaker CB3 and ammeter M2 to positive batteryc o n n e c t o r P 3 , t h r o u g h t h ebattery under charge to negativebattery connector P2, throughcircuit breaker CB2 to the neg-a t i v e t e r m i n a l o f r e c t i f i e rCR1.

5

Figure 2.

TM

6130-227-45-2

6

CHAPTER 3

MAINTENANCE INSTRUCTIONS

Section I. GENERAL

5. Scope of Field and Depot Maintenance nance duties are the same as fourth ech-a. Third Echelon. No maintenance is elon (b above) and include also complete

performed at third echelon. overhaul of the equipment and final test-b. Fourth Echelon. Fourth echelon ing (para 17 through 21) for return to

maintenance of the PP-1660/G consists service or to depot stock.of the following:

(1) Routine maintenance (para 7 and 8). 6. Tools, Materials, and Test Equipment(2)

(3)

(4)

Troubleshooting (para 9 through The following tools, materials, and test13). equipment are required for routine main-Replacement of authorized main- tenance, troubleshooting, and repair:tenance parts (para 14 and 15). a. Tool Kit TK-87-A.Testing performance for return to b. Cleaning Compound (FSN 7930-395-service (para 16). 95421.

c. Fifth Echelon. Fifth echelon mainte- C. Multimeter TS-352/U (TM 11-5527).

Section II. ROUTINE MAINTENANCE

7. Scope of Routine Maintenance

a. Duties. Routine maintenance of thePP-1660/G consists of the following:

(1) Cleaning the interior of the equip-ment (para 8 a).

(2) Inspecting interior parts andwiring (para 8 b).

(3) Tightening loose connections andmounting hardware (para 8 b).

b. Intervals. Perform routine mainte-nance regularly in accordance with aschedule established on the basis of daysor months of use, with consideration forthe conditions under which the equipmentis operated. For maintenance purposes,a day consists of 8 hours of operationand a month consists of 30 days of 8-houroperation. It is recommended that routinemaintenance of the PP-1660/G be per-formed monthly, or more frequently underadverse operating conditions, such as existin very hot, humid, or dusty areas.

8. Routine Maintenance Procedures

Warning: Place the CHARGE SWITCHin the OFF position and disconnect the ac

input cable from the ac supply beforeservicing the PP-1660/G. Never performroutine maintenance with the power on.

a. Cleaning. Remove the cover of thebattery charger (para 15a) and clean theinterior of the equipment. Use a clean,dry cloth to remove dust and dirt. If neces-sary, use a cloth dampened with cleaningcompound and then wipe thoroughly drywith a clean, dry cloth. If available,vacuum cleaning equipment or dry com-pressed air may be used to remove loosedust and dirt. If compressed air is used,the pressure must be low enough to pre-vent damage to the equipment. Be surethe front, bottom, and rear ventilatinggrilles are thoroughly clean and free offoreign matter that might obstruct the freecirculation of air.

Warning: Cleaning compound is flam-mable and its fumes are toxic. Do not usenear a flame and provide adequate venti-lation.

b. Inspection. Inspect all interior partsand wiring carefully for evidence of incip-ient malfunction or failure.

7

(1)

(2)

(3)

See that all parts are mountedsecurely. Tighten loose mountinghardware and replace any that ismissing.See that all switch contacts are

(4) See that the impeller is mountedsecurely on the hub of the blowermotor and that it rotates freelyand has adequate clearance. see that all wiring is in good con-

clean and tight; clean and tighten,(5)

if necessary.Inspect the transformer, reactor,

dition and that connections areclean and tight. If necessary, cleanand tighten connections; replace

and rectifiers for evidence ofoverheating.

wiring that shows evidence of dete-rioration.

Section III. TROUBLESHOOTING

Warning: Be extremely careful when performing troubleshooting with the power on.Use insulated test probes when making voltage measurements. Always disconnect the acinput cable before touching any internal part.

9. Scope of Troubleshooting

Troubleshooting at the field and depotmaintenance level includes all the tech-niques outlined for operator’s and organ-izational maintenance and all additionaltechniques required to isolate a defectivepart. The field and depot maintenanceprocedures are not complete in them-selves, but supplement the proceduresdescribed in TM 11-6130-227-12.

10. Troubleshooting Procedures

The first step in servicing a defectivebattery charger is to sectionalize the faultto a major circuit group. The second stepis to localize the trouble to an individualcircuit that is not functioning properly,and the final step is to isolate the defec-tive part.

a. Operational Checks. Most trouble inthe PP-1660/G can be sectionalized to theac input circuits, the transforming cir-cuits, the rectifying circuits, or theswitching circuits by systematic checksof the performance of the equipment.Examine the repair tag to see whetherthe trouble has been sectionalized andlocalized by first and second echelonpersonnel. If the trouble has not beenlocalized, check the performance of theequipment in accordance with the equip-ment performance checklist and thetroubleshooting instructions in TM 11-6130-227-12.

8

b. Visual Inspection. Before disassem-bling the equipment, inspect it. Many de-fective parts can be identified by sight,touch, or smell. Remove the cover of thecase (para 15 a) and inspect all internalparts and wiring carefully for evidenceof damage such as the following:

(1)

(2)

(3)

(4)

Loose or broken connections anddefective wiring.Loose or missing mounting hard-ware and broken or otherwisephysically damaged parts.

Warning: The failure of seleni-um rectifiers can result in theliberation of poisonous fumes andthe deposit of poisonous seleniumcompounds. When a rectifier burnsout or arcs over, the odor isstrong. Provide maximum venti-lation immediately. Avoid inhalingthe fumes. Do not touch the dam-aged rectifier until it has cooled.Blistered, buckled, or discoloredrectifier plates.Evidence of overheated trans-former, reactor, or blower motor.

c . T r o u b l e s h o o t i n g C h a r t . Usethe troubleshooting chart (para 11) as anaid in determining the probable causes ofthe symptoms of faulty operation and thecorrective measures required.

d. Tests. Use Multimeter TS-352/U toperform point-to-point continuity tests andto make voltage and resistance measure-ments (para 12 and 13) to determine the

condition of individual parts. Refer to point-to-point wiring and connectionthe schematic diagram (fig. 2) to iden- points.tify circuit components and test pointsand to the wiring diagram (fig. 5) for 11. Troubleshooting Chart

9

P r o b a b l e c a u s eCorrective measure

Check rectifier CRl (IXU8 1~);

replace rectifier asaembly

(Pam 15j) if ciefectlve.

Check transformer ~ wimifng

6-8 @ra Ma); if defective,

replace transformer T1 (part

15J).

Replace circuit breaker CB2

@a 15M).

Check relay K5 (pare GM and 13);

replace (para 15 m) if defective.

Check relay K4 (para l?d and 13);

replace (para 15m) if defective.

Replace BATTERY VOLTS switch

S2 (para 15h).

Replace C HAIW3E SWITCH S1

(para 15g).

Check connections of ammeter

M2 to slamt reaistcr Rl; replace

ammeter M2 (puma 15Z) if defec-

tive.

Check circuit breakera CB2 and

CB3; replace defective circuit

braakr (para 15m).

Replace m SWITCH Ml (pe.ra

Ieif).

Replace TIME SWITCH Ml @era

1~.

Check reactor Ll @ra 13);

replace (pare 151c) If defective.

Check rectifiers CRl mid CR2

(para 12b); replace rectifier

aasembly (para 15j) if m8aUa-

factorg.

Symptom

Charging rata Mghor @m 40 ampe~s

cannot be ob~d in 12-volt faat

cha@nJ3 ,

Rectifier CRl defective ------------

Transformer Tl defective ----------

Circuit breaker CB2 defective ------

Relay K5 defective -----------------

Relay K4 defective -----------------

BATTERY VOLTS switch S2 defective

CHARGE SWITCH S1 defective ------

Ammeter M2 disconnected or defec-

tive.

Circuit breaker CB2 or CB2 defective

Clock of TIME SWITCH Ml defectiva

TIME SWITCH Ml defective --------

Reactor Ll defective ---------------

Rectifiers CB1 and CB2 aged or

defective.

NO dc output with BATTERY VOLTS

switch S2 in 24 psition; out@ with

BATTERY VOLTS switch S2 in 6 or

12 position aatlefactory.

Charging rate doea not ticreaae when

CHARGE SWITCH S1 iS adVtUICed to

MED and HfGH.

Battery charger operatfng but ammeter

M2 does not indicate any dc output.

Battery charger stope whenever 40-

ampere charging rate ia excaeded

tiring 6-or 12-volt charging.

TIME SWITCH Ml doee not return b

SLOW CHARGE pcaition.

Charging rate does not drop back into

slow-charge rauge when TIME

SWITCH Ml returna to SLOW CHARGI

poeition.

Maximum cbarglng rata in faat-charge

~ cannot be obtained.

1 2 . V o l t a g e M e a s u r e m e n t s

b . R e c t i f i e r s C R 1 a n d C R 2 . W i t h t h e

b a t t e r y c h a r g e r o p e r a t i n g i n t h e f a s t -

c h a r g e r a n g e , t h e B A T T E R Y V O L T S

s w i t c h a t 1 2 , a n d t h e c h a r g i n g r a t e a d -

j u s t e d t o 7 5 a m p e r e s , m e a s u r e t h e v o l t -

a g e a c r o s s e a c h l e g o f r e c t i f i e r s C R 1

a n d C R 2 . T h e d i f f e r e n c e b e t w e e n t h e

h i g h e s t a n d t h e l o w e s t v o l t a g e r e a d i n g

o b t a i n e d s h o u l d n o t e x c e e d 0 . 3 v o l t .

c . R e l a y K 1 . R e l a y K 1 s h o u l d o p e r a t e

w h e n 1 6 t o 1 8 v o l t s i s a p p l i e d t o i t s c o i l

( a c r o s s t e r m i n a l s 1 - 2 ) a n d s h o u l d r e l e a s e

w h e n t h e v o l t a g e i s r e d u c e d t o a p p r o x i -

m a t e l y 1 3 v o l t s .

W a r n i n g : B e e x t r e m e l y c a r e f u l w h e nm a k i n g v o l t a g e m e a s u r e m e n t s . U s e i n -

s u l a t e d t e s t p r o b e s a n d d o n o t t o u c h a n y

i n t e r n a l p a r t o f t h e b a t t e r y c h a r g e r w h i l e

i t i s e n e r g i z e d .

a . T r a n s f o r m e r T 1 . W i t h t h e b a t t e r y

c h a r g e r o p e r a t i n g i n t h e f a s t - c h a r g e r a n g e

a n d t h e C H A R G E S W I T C H a t L O W ( t h e

B A T T E R Y V O L T S s w i t c h m a y b e i n a n y

p o s i t i o n ) , t h e v o l t a g e s s h o w n i n t h e c h a r t

b e l o w s h o u l d b e o b t a i n e d b e t w e e n t h e

t e r m i n a l s i n d i c a t e d .

Winding Terminals Volts

Primary 1-6

2-5

3-6

4-s

Secondary 6-8

6-7

115

106.5

99.0

93.0

15,0

7,5

10

d. Relays K2 Through K6. Relays K2through K6 each should operate when avoltage of : -- ;ts (maximum) is appliedto its coil (across terminals 1-2).

13. Resistance Measurements

Make all resistance measurements withthe equipment deenergized and with thepart disconnected from the remainder ofthe circuit. The approximate resistances

of the winding of reactor L1 and of thecoils of relays K1 through K6 are givenin the chart below.

Section IV. REMOVAL AND REPLACEMENT OF PARTS AND TESTING AFTER REPAIRNote: All maintenance parts for Charger, Battery PP-1660/G (TM-11-6130-227-45P) are replaceable at

fourth echelon.

14. General Procedures

All parts of the PP-1660/G, excepttransformer T1, are readily accessiblewhen the cover of the case is removed andcan be removed and replaced individuallywithout first removing any other parts.Instructions for the removal and replace-ment of all functional parts are providedin paragraph 15. When removing parts orrepairing wiring, tag leads and mark ter-minals for positive identification beforedisconnecting any wiring to assure cor-rect reconnection. When wiring is re-placed, use wire that conforms with thatspecified in figure 5.

15. Removal and Replacement of PartsNote: Most parts can be reinstalled by remounting

them in their original location with the originalhardware and reconnecting the leads. Replacementinstructions are given only when special proceduresor precautions are required.

a. Cover (1, fig. 3). Remove four screwsfrom the top and three screws from eachside of the cover and carefully lift off thecover. The blower assembly is mountedin the cover; be sure not to strain or breakthe leads connected to the blower motor(2). When replacing the cover, be surethere is adequate clearance for the blowermotor leads.

b. Blower Assembly (2 and 3, fig. 3).Remove the two hexagonal nuts that fastenblower motor B1 (2) to the shroud (11).Disconnect the leads at blower motor B1and lift out the blower assembly. To re-move impeller MP3 (3), loosen the set-

screw in the hub and pull impeller MP3off the shaft of motor B1.

c. Ac Input Cable (4, fig. 3). Disconnectone cable lead from TIME SWITCH M1(7) and unsolder and disconnect the othercable lead from the solder connection(fig. 5). Release the strain relief bushing(not shown) in the back of the case (12,fig. 3) and pull out the ac input cable.When reinstalling the ac input cable, con-nect the cable lead with a lug to TIMESWITCH M1 (7). Splice the other cablelead to one lead of blower motor B1 (2)and the black lead from the primary wind-ing of transformer T1 (fig. 5). Solder theconnection and tape securely.

d. Dc Output Cables (5, fig. 3). The pos-itive (red connector) dc output cable isconnected to resistor R1 (5, fig. 4) andthe negative (black connector) dc outputcable is connected to circuit breaker CB2(6). To remove either dc output cable,disconnect it, release the strain reliefbushing (not shown) in the back of the case(12, fig. 3), and pull out the cable.

e. Ammeter M2 (10, fig. 3). Disconnectthe leads, remove the mounting screwsand nuts, and carefully remove ammeterM2 from the front panel from the front.When reconnecting the ammeter leads,be sure to observe correct polarity (fig. 5).

f. TIME SWITCH M1 (7, fig. 3). Loosenthe two setscrews that secure TIMESWITCH knob MP12A (6) and pull the knoboff the shaft. Disconnect the leads, re-move the locknut, and remove TIMESWITCH M1 from the front panel from the

11

TM6130-227-45-3

Figure 3. Charger, battery PP-1660/G cover removed.12

rear. When reinstalling TIME SWITCHM1, rotate the shaft fully counterclock-wise and install TIME SWITCH knob MP-12A (6) so that the pointer is at SLOWCHARGE. Be sure to tighten both set-screws.g. CHARGE SWITCH S1 (1, fig. 4).Loosen the two setscrews that secureCHARGE SWITCH knob MP12B (9, fig. 3)and pull the knob off the shaft. Discon-nect the leads, remove the locknut, andremove CHARGE SWITCH S1 from thefront panel from the rear. When reinstal-ling CHARGE SWITCH S1, rotate theshaft fully counterclockwise and reinstallCHARGE SWITCH knob MP12B (9) sothat the pointer is at OFF. Be sure totighten both setscrews.

h. BATTERY VOLTS Switch S2 (2, fig.4). Pull BATTERY VOLTS switch knobMP11 straight forward off the shaft. Dis-connect the leads, remove the locknut, andremove BATTERY VOLTS switch S2 fromthe front panel from the rear. When re-installing BATTERY VOLTS switch S2,rotate the shaft fully counterclockwise andreinstall BATTERY VOLTS switch knobMPP11 so that the engraved pointer is at6.

i. Circuit Breaker CB1 (4, fig. 4). Cir-cuit breaker CB1 is mounted on a bracketfastened to the top flange of transformerT1 (14). To remove circuit breaker CB1,disconnect the leads and remove the nuts,lockwashers, and screws that fasten cir-cuit breaker CB1 to its bracket.

j. Rectifiers CR1 and CR2. RectifiersCR1 and CR2 (not shown) are connectedtogether and are removed as an assembly.The rectifier assembly is mounted on topof transformer T1 (14, fig. 4). To removethe rectifier assembly, take out the fourscrews that secure it to transformer T1,disconnect all leads, and lift the rectifierassembly out of the case. Be careful notto bend or otherwise damage the rectifierplates during removal or replacement ofthe rectifier assembly.

k. Reactor L1 (3, fig. 4). Reactor L1 is

mounted in front of transformer T1 (14).To remove reactor L1, disconnect the twopigtail leads from TIME SWITCH M1 (7,fig. 3) and circuit breakert CB1 (4, fig. 4),remove the two mounting screws, acces-sible from the bottom of the case, andlift out reactor L1.

l. Transformer T1 (14, fig. 4). Removerectifiers CR1 and CR2 (j above) and cir-cuit breaker CB1 (i above); it is not nec-essary to disconnect circuit breaker CB1.Disconnect the 11 pigtail leads of trans-former T1, remove the four mountingscrews, and lift transformer T1 out of thecase. When reinstalling transformer T1,be sure to solder and tape the connectionto the ac input cable lead and the blowermotor lead (fig. 5) securely.m. Subpanel (15, fig. 4). The subpanel

is a U-shaped, sheet-metal chassis onwhich are mounted relay K1 (13), relaysK2 through K6 (8 through 12), and circuitbreakers CB2 (6) and CB3 (7). The sub-panel is located behind transformer T1 andis fastened to the case by three screws.Parts mounted on the subpanel can be re-moved individually (without removing thesubpanel) by disconnecting their leads andremoving the mounting hardware. To re-move the subpanel as an assembly, it isnecessary first to disconnect all leadsconnected to parts not mounted on the sub-panel (fig. 5).

n. Resistor R1 (5, fig. 4). Resistor R1is mounted on the inside of the back of thecase by means of the same screw and acornnut that secure the lower hanger of the acinput cable to the outside of the case. Toremove resistor R1, disconnect the leadsfrom its terminals and remove the acornnut and the screw.

16. Testing After Repair

Whenever the battery charger has beenrepaired, check the overall operation ofthe equipment. Follow the procedure out-lined in the equipment performance check-list (TM 11-6130-227-12).

13

T M 6 1 3 0 - 2 2 7 - 4 5 - 5

Figure 4. Charger, Battery PP-1660/G, major internal parts (less rectifiers CR1 and CR2)r e m o v e d f r o m c a s e .

14

Figure 5.

TM

6130-227-45-7

15

CHAPTER 4

FINAL TESTING

17. Purpose of Final Testing

The tests outlined in this chapter aredesigned to measure the performance ca-pability of a repaired equipment. Equip-ment that meets the standards stated inthe tests will give satisfactory perform-ance, equivalent to that of new equipment.

18. Test Equipment for Final Testing

The following test equipment is requiredfor final testing the PP-1660/G:

a. Ohmmeter ZM-21/U (TM 11-2050A).b. Ammeter AN/USM-69.c. Ammeter ME-65/U.d. Test Set, Generator and Low Voltage

Regulator TV-100.e. Source of regulated 115-volt, 60-CPS

ac, capable of carrying a load of 20 am-peres.

19. Physical Inspection

Visually inspect the complete unit. Seethat the case is in good condition and thatall parts are mounted securely, all cablesand tiring are in good condition, and allconnections are clean and tight. Pay par-ticular attention to the following:

a. Inspect the connections betweentransformer T1 and CHARGE SWITCH S1and the connections to BATTERY VOLTSswitch S2 to be sure they are correct.Refer to figure 5 for proper connections.

b. Inspect the subpanel assembly to seethat the circuit breakers and relays aremounted properly and that all connectionsare correct (fig. 5).

Inspect the rectifier assembly to seethat it is fastened securely to transformerT1 and that all bus bar and cable connec-tions are correct (fig. 5) and are in goodcondition.

d. Inspect the blower assembly to seethat the impeller is secure on the shaft ofthe blower motor and that the blades rotatefreely and have adequate clearance.

16

20. Insulation Resistance Tests

a. Input Circuit.(1)

(2)

(3)

Connect the line binding post ofOhmmeter ZM-21/U to one of thecontacts of the ac input cable plugconnector and connect the groundbinding post of the ZM-21/U to abare spot on the case of the batterycharger.Set TIME SWITCH Ml to SLOWCHARGE and set CHARGE SWITCHS1 to LOW.Operate the ZM-21/U and read theohmmeter; the resistance shouldbe not less than 1 megohm.

b. Output Circuits.Caution: Be sure not to allow the con-

nectors of the dc output cables to toucheach other during this test or the equip-ment will be damaged seriously.

(1)

(2)

(3)

(4)

(5)

Connect the line binding post of theZM-21/U to the connector of thepositive dc output cable and con-nect the ground birding post of theZM-21/U to a bare spot on the caseof the battery charger.Set BATTERY VOLTS switch S2 to6. Operate the ZM-21/U and readthe ohmmeter.Set BATTERY VOLTS switch S2 to12 and then to 24. Operate the ZM-21/U and read the ohmmeter withBATTERY VOLTS switch S2 ineach positionConnect the line binding post of theZM-21/U to the connector of thenegative dc output cable and re-peat the procedure outlined in (2)and (3) above.The resistance reading obtainedin each case ((2), (3), and (4) above)should be not less than 1 megohm.

c. Primary to Secondary of Trans-former T1.

(1) Connect the line binding post of theZM-21/U to one of the contacts o

i. On the TV-100, set the voltage rangeswitch to the 50-volt range and set theBATTERY VOLTS switch on the PP-1660/G to 24.

j. Adjust the carbon pile control of theTV-100 so that the D.C. AMPERES meterindicates 40 amperes, and check for thefollowing meter indications:

k. On the PP-1660/G, slowly turn theCHARGE SWITCH counterclockwise, oneposition at a time, to MED and then toLOW. The charging rate indicated by thePP-1660/G ammeter should decrease witheach change in the setting of the CHARGESWITCH and the AN/USM-69 readingshould agree with the PP-1660/G ammeterreading within about ±4 amperes.

l. Return the CHARGE SWITCH to HIGHand set the TIME SWITCH at SLOWCHARGE. The PP-1660/G ammeter shouldindicate approximately 25 amperes and theTV-100 D. C. VOLTS meter should indicate15 ±3 volts. After a short time, all meter

indications should drop to 0, indicatingthe circuit breaker CB1 has opened.

m. Set the CHARGE SWITCH on the PP-1660/G and the load bank switch on the TV-100 to OFF.

n. Disconnect the AN/USM-69 from thePP-1660/G and the TV-100, and discon-nect the ME-65/U from the ac input sideof the PP-1660/G.

o. Connect the PP-1660/G positive dcoutput cable to the 24V binding post of theTV-100 and connect the negative dc outputcable to the highest range ammeter bindingpost. Connect the PP-1660/G ac inputcable directly to the 115-volt ac supply.

p. On the PP-1660/G, set the TIMESWITCH to 5, the BATTERY VOLTS switchto 6, and the CHARGE SWITCH to LOW.

q. Set the TV-100 load bank switch toON and adjust the carbon pile control sothat the D. C. AMPERES meter indicatesapproximately 150 amperes; the PP-1660/G ammeter pointer may go off-scale to theright.

Note. The PP-1660/G ammeter will withstand a200-percent overload without becoming damaged.

r. After a few seconds, the PP-1660/Gammeter indication should drop sharply,indicating that either circuit breaker CB2or circuit breaker CB3 has opened, orshould drop to 0 indicating that circuitbreakers CB2 and CB3 both have opened.

s. After approximately 1 to 2 minutes,the PP-1660/G ammeter indication shouldincrease sharply indicating that circuitbreakers CB2 and CB3 have closed.

t. Set the PP-1660/G CHARGE SWITCHand the TV-100 load bank switch to OFFand disconnect the PP-1660/G from theTV-100 and from the ac supply.

18

TM 6130-227-45-6

(2)

(3)

(4)

(5)

Figure 6. Charger, Battery PP-1660/G, connections for functions tests.

the ac input cable plug connectorand connect the ground bindingpost of the ZM-21/U to either oneof the dc output cables.Set TIME SWITCH M1 to SLOWCHARGE and set CHARGE SWITCHS1 to LOW.Set BATTERY VOLTS switch S2to 6. Operate the ZM-21/U and readthe ohmmeter.Set BATTERY VOLTS switch S2 to12 and then to 24. Operate the ZM-21/U and read the ohmmeter withBATTERY VOLTS switch S2 ineach position.The resistance reading obtained ineach case ((3) and (4) above) shouldbe not less than 1 megohm.

21. Function Testsa. Set the CHARGE SWITCH on the PP-

1660/G and the load bank switch on theTV-100 to OFF.

b. Connect test equipment to the PP-1660/G as shown in figure 6.

c. On the TV-100, rotate the carbon pilecontrol counterclockwise until the knobturns freely and set the voltage rangeswitch to the 10-volt range.

d. On the PP-1660/G, set the TIME

SWITCH at 10, the BATTERY VOLTSswitch at 6, and the CHARGE SWITCH atHIGH.

e. On the TV-100, rotate the carbonpile control clockwise until a slight re-sistance is felt; then place the load bankswitch at ON and adjust the carbon pilecontrol so that the D.C. AMPERES meterindicates 70 amperes.

f. Check for the following meter indi-cations:

g. On the TV-100, set the voltage rangeswitch to the 20-volt range and set theBATTERY VOLTS switch on the PP-1660/G to 12.

h. Adjust the carbon pile control of theTV-100 so that the D.C. AMPERES meterindicates 70 amperes, and check for thefollowing meter indications:

17

APPENDIXREFERENCES

TM 11-2050A Ohmmeter ZM-21/UTM 11-5527 Multimeters TS-352/U, TS-352A/U, and TS-352B/UTM 11-6130-227-12 Operator and Organizational Maintenance Manual: Charger,

Battery PP-1660/GTM 11-6130-227-20P Organizational Maintenance Repair Parts and Special Tools

List: Charger, Battery PP-1660/GTM 11-6130-227-45P Field and Depot Maintenance Repair Parts and Special Tools

List: Charger, Battery PP-1660/G

19

By Order of Secretary of the Army:

Official:J. C. LAMBERT,

Major General, United States Army,The Adjutant General.

Distribution:

Active Army:

DASA (6)USASA (2)CNGB (1)Tech Stf, DA (1) except

CSigO (14)Tech Stf Bd (1)USCONARC (5)USAARTYBD (1)USAARMBD (2)USAIB (1)USARADBD (2)USAAVNBD (1)USA Abn, Elct & SPWAR Bd (1)USAATBD (1)ARADCOM (2)ARADCOM Rgn (2)OS Maj Comd (3)OS Base Comd (2)LOGCOMD (2)MDW (1)Armies (2)Corps (2)Instls (2)Ft Monmouth (63)USATC AD (2)USATC Engr (2)USATC Inf (2)USATC FA (2)USATC Armor (2)USAOMC (2)Svc College (2)Br Svc Sch (2)GENDEP (2) except

Atlanta GENDEP (None)Sig Sec, GENDEP (5)

NG: None.USAR: None.For explanation of abbreviations Used see AR 320-50.

G. H. DECKER,General, United States Army,

Chief of Staff.

Sig Dep (12)WRAMC (1)USA Trans Tml Comd (1)Army Tml (1)POE (1)OSA (1)USAEPG (2)AFIP (1)AMS (1)Army Pictorial Cen (2)EMC (1)Yuma Test Sta (2)USA Strat Comm Comd (4)USASSA (20)USASSAMRO (1)USARCARIB Sig Agcy (1)USA Sig Msl Spt Agcy (13)Sig Fld Maint Shops (3)Def Log Svc Cen (1)USA Corps (3)JBUSMC (2)Units org under fol TOE (2 cy ea UNOINDC)

11-711-1611-5711-9811-11711-15511-15711-500 (Tins AA-AE) (4)11-55711-58711-59211-59711-97

20

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