TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
wire.
(2)
Crimp lugs on lead wires, then install resistor (38) into clip (41). Secure lugs (36) to standoff (37) with nuts
(35).
Section II. BATTERY CHARGER
4-5. GENERAL. This section covers inspection, replacement, testing, and repair of the battery charger.
4-6. DESCRIPTION. The battery charger transforms 120V AC to 24V DC at 20 amperes to charge the generator set
batteries. It automatically senses the condition of the batteries and delivers the amount of current required to keep the
batteries fully charged. The battery charger has a built-in cut out relay to prevent battery drain in the event of an AC
power failure. Figure 4-3 is the battery charger schematic.
4-7. INSPECTION. Check battery charger input and output cable connections for looseness or corrosion. Check all
components for loose mounting, poor solder connections, broken wires, overheated resistors, or any other signs of
damage.
4-8. REMOVAL AND REPLACEMENT.
a. Removal. (See figure 4-1.) The battery charger (45, figure 4-1) is mounted to the right side wall of the AC-DC
control box assembly enclosure. Open door (73) and remove as follows:
WARNING
BEFORE STARTING ANY MAINTENANCE PROCEDURE, SET MAINTENANCE LOCK-OUT SWITCH
TO LOCKOUT. DISCONNECT NEGATIVE CABLE FROM BATTERIES. REMOVE EXTERNAL
POWER BY OPENING CB101 (EXTERNAL POWER CIRCUIT BREAKER) AND DISCONNECTING
POWER CABLE FROM RECEPTACLE J101 (120V RECEPTACLE).
(1)
Open battery charger door.
Legend For Figure 4-1
1. Screw
29. Nut/washer
57A.Lug
2. Nut/washer
30. Terminal block
58A.Washer
3. Ac-dc panel
31. Screw
59. Screw
4. Spacer bar
32. Nut
60. Clip
5. Stripping
33. Relay K20
61. Screw/washer
6. Screw
34. Screw
62. Bracket
7. Cover
35. Nut
63. Screw
8. Connector
36. Lug
64. Washer
9. Washer
37. Standoff
65. Washer
10. Nut
38. Resistor
66. Nut
11. Screw/washer
39. Screw
67. Screw
12. Nut
40. Nut
67A.Washer
13. Screw, washer
41. Clip
68. Washer
14. Nut
42. Screw
69. Nut
15. Screw
43. Panel
70. Ac-dc box
16. Nut/washer
44. Screw/washer
71. Screw
17. Clamp
45. Battery charger
72. Nut
18. Clamp
46. Screw
73. Door assembly
19. Clamp
47. Washer
74. Seal
20. Clamp
48. Voltage Regulator
75. Enclosure assembly
21. Screw/washer
49. Screw
22. Clamp
50. Nut
23 Harness
51. Clamp
24. Screw
52. Screw
25. Nut/washer
53. Nut
26. Terminal block
53A.Resistor assembly
26A.Jumper
54. Potentiometer
27. Diode
55. Lock
27A.Lug
56. Governor
28. Screw
57. Sleeve
4-2
