4-5. BATTERY CHARGER BC1 DISASSEMBLY

Figure 4-1. Battery Charger BC1, Schematic

Figure 4-2. Battery Charger BC1, Exploded View (Sheet 1 of 2)

TM-9-6115-604-34 Generator Set Diesel Engine Driven Tactical Skid Mtd 5 Kw. 1 Phase-2 Wire 1 Phase -3 Wire 3 Phase -4 Wire 120. 120/240 and 120/208 Volts Manual
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TM 9-6115-604-34 NAVFAC P-8-633-34 4-5. BATTERY CHARGER BC1 DISASSEMBLY NOTE When necessary, remove components that have been soldered in place by unsoldering. a. Tag and disconnect wiring. b. Remove the front cover (3, Figure 42) from the enclosure (6), and remove the nameplate (2), if necessary, by removing the rivets (1). c. Remove the hexagon head screws (11) and flat washers (10), and remove the resistor (8) from the enclosure (6). Remove the retaining clip (44). d. Remove the hexagon head screws (12), and remove the resistor (9) from the enclosure (6). e. Remove the hexagon head screws (4) and lockwashers (5), and separate the enclosure rear panel (7) from the enclosure (6). f. Remove the screws (13), and remove the fuse board (14) from the transformer (24). Remove the output fuse (15) and the input fuse (16) from the fuse board (14). Remove the fuse holders (45 and 46). g. Remove the hexagonal nut (19) and lockwasher (18), and remove the cut out relay (21) from the bracket (20). Remove the fixed capacitor (22). h. Remove the hexagon head screw (17), and remove the bracket (20) from the enclosure rear panel (7). i. Remove the hexagon head screws (23), and remove the transformer (24) from the enclosure rear panel (7). j. Remove the hexagon head screws (25), hexagonal nuts (26), lockwashers (27), and flat washers (28), and remove the reactor assembly (29) from the enclosure rear panel (7). k. Remove the capscrews (30), and remove the terminal board (31) from the enclosure rear panel (7). Remove the screw and captive washer assemblies (32), and remove the zener resistor (33) from the terminal board (31). Remove the round head screws (34), and remove the transistor (35) from the terminal board (31). Remove the diode (43) and the zener diode (47) from the terminal board. l. Remove the capscrews (36), and remove the heatsink (37) from the enclosure rear panel (7). Remove the silicone diodes (38) from the heatsink (37). 4-6. CLEANING, INSPECTION, AND REPAIR OF BATTERY CHARGER BC1. Disassemble battery charger BC1 in accordance with paragraph 4-5, and reassemble after repair in accordance with paragraph 4-7. Refer to Figure 4-2. a. Inspect the battery charger BC1 for signs of corrosion, loose electrical connections, worn or broken wiring, poor or broken soldered connections. Clean corroded components. Tighten loose electrical connections, and repair worn wiring and poorly or broken soldered connection in accordance with MIL-STD4, Requirement 5. Replace broken wires as necessary. b. Inspect the DC voltmeter (40) and DC ammeter (41) for secure panel mounting and for chipped, cracked, or loose cover glass, and broken indicators. Inspect the equalizer timer (39) for secure panel mounting. Ensure that the timer knob rotates freely and remains positioned as set. c. Inspect the output and input fuse (45 and 46) dips for signs of damage or deterioration, and check with an ohmmeter set to the RX1 scale. An ohmmeter connected across the ends of either the output or input fuse (15 or 16) should indicate continuity. A reading of infinity indicates a blown fuse. Replace the output and the input fuses (15 and 16) as necessary. d. Inspect the insulation of transformer (24) and reactor assembly (29) for signs of deterioration or damage by using 500 V dc megohmmeter. If the insulation of transformer (24) or reactor assembly (29) is damaged or shows signs of deterioration, the unit must be replaced. 4-3

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