TECHNICAL MANUAL DIRECT SUPPORT

TM 11-6130-356-34

TECHNICAL MANUAL

DIRECT SUPPORT

AND

GENERAL SUPPORTMAINTENANCE MANUAL

POWER

(NSN

SUPPLY PP-6148/U

6130-01-062-3618)

This copy is a reprint which includes currentpages from Change 1.

HEADQUARTERS, DEPARTMENT OF THE ARMY10 MAY 1982

TM 11-6130-356-34C1

CHANGE

No. 1

HEADQUARTERSDEPARTMENT OF THE ARMY

Washington, DC, 15 September 1987

DIRECT SUPPORTAND GENERAL SUPPORT MAINTENANCE MANUAL

POWER SUPPLY PP-6148/U(NSN 6130-01-062-3618)

TM 11-6130-356-34, 10 May 1982, is changed as follows:

1. Remove old pages and insert new pages as indicated below. New or changed material is indicated by a vertical barin the margin of the page. Added or revised illustrations are indicated by a vertical bar adjacent to the identificationnumber.

Remove pages Insert pages

A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. A and Bi, ii, and iii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i through iii/(iv blank)l-land l-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-1 and l-2None . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2.1/(1-2.2 blank)l-3 through l-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-3 through l-62-l through 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-l through 2-43-l through 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-l through 3-63-15 through 3-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 through 3-303-33 and 3-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..3-33 and 3-344-l through 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-l through 4-4Figure FO-3(l) through F0-3(1) . . . . . . . . . . . . . . . . . . Figure FO-3(1) through FO-3(3)

2. File this change sheet in the front of the publication for reference purposes.

Distribution authorized to the Department of Defense and DOD contractors onlyfor official use or for administration or operational purpsoes. This determinationwas made on 4 May 1987. 0ther requests for this document will be refurredto Commander, US Army Communications-ElectronicsMonmouth, ATTN: AMSL-ME-P, Fort Monmouth, NJ 07703-5000

DESTRUCTION NOTICE-Destroy by any method that wiIIprevent disclosure of contents or reconstruction of thedocument.

By Order of the Secretary of the Army:

Official:

R.L. DILWORTHBrigadier General, United States Army

The Adjutant General

CARL E. VUONOGeneral, United States Army

Chief of Staff

DISTRIBUTION:To be distr ibuted in accordance with DA Form 12-51 l i terature

requirements for PP-6148/G.

TM 11-6130-356-34

SAFETY STEPS TO FOLLOW IF SOMEONEIS THE VICTIM OF ELECTRICAL SHOCK

DO NOT TRY TO PULL OR GRAB THE INDIVIDUAL

IF POSSIBLE, TURN OFF THE ELECTRICAL POWER

IF YOU CANNOT TURN OFF THE ELECTRICALPOWER, PULL, PUSH, OR LIFT THE PERSON TOSAFETY USING A DRY WOODEN POLE OR A DRYROPE OR SOME OTHER INSULATING MATERIAL

SEND FOR HELP AS SOON AS POSSIBLE

AFTER THE INJURED PERSON IS FREE OFCONTACT WITH THE SOURCE OF ELECTRICALSHOCK, MOVE THE PERSON A SHORT DISTANCEAWAY AND IMMEDIATELY START ARTIFICIALRESUSCITATION

Change 1

TM 11-6130-356-34

WARNINGS

● High voltages and currents exist in this equipment. Serious injury or deathmay result from contact with the output terminals or internal circuitry.Reenergize the equipment before connecting or disconnecting test equip-ment.

● Do not attempt internal service or adjustment unless another person,capable of rendering first aid and resuscitation, is present.

Be sure to discharge capacitors before troubleshooting and repair.

● Adequate ventilation must be provided while using TRICHLOROTRI-FLUOROETHANE. Prolonged breathing of vapor must be avoided. Thesolvent must not be used near heat or open flame; the products of decom-position are toxic and irritating. Since TRICHLOROTRIFLUORO-ETHANE dissolves natural oils, prolonged contact with skin must beavoided. When necessary, use gloves which the solvent cannot penetrate. Ifthe solvent is taken internally, consult a physician immediately.

Prevent personal injury when applying or removing steel strapping, bywearing heavy gloves and protective eyewear. Do not handle packingcartons by the steel strapping.

● Explosive gases may be released during battery charging operations. Besure that the charging area is well ventilated. Do not use matches or an openflame in the charging area. Guard against short circuits; resulting arcs maycause an explosion. Do not disconnect the battery charger adapter cablefrom the battery until the DC ON-OFF circuit breaker is set to OFF, andthe battery charger adapter cable is disconnected from the power supply.Do not attempt to charge a damaged or leaking battery.

On serial numbers 1A through 154A, momentarily turn the AC ON-OFFcircuit breaker first to the ON position, and then to the OFF position afterdisconnecting AC power input cable assembly W1. This action will dischargeany voltage present at the terminals of AC INPUT connector J1, and isrequired to avoid electrical shock hazard.

B Change 1

TM 11-6130-356-34

T ECHNICAL M A N U A L HEADQUARTERSDEPARTMENT OF THE ARMY

N0.11-6130-356-34 W ASHINGTON , DC, 10 May 1982

DIRECT SUPPORT AND GENERAL SUPPORT

MAINTENANCE MANUAL

POWER SUPPLY PP-6148/U

(NSN 6130-01-062-3618)

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. lf you find any mistakes or if you know of away to improve the procedures, please let us know. Mail your letter, DA Form 2028(Recommended Changes to Publications and Blank Forms), or DA 2028-2 located inback of this manual direct to Commander, US Army Communications-ElectronicsCommand and Fort Monmouth, ATTN: AMSEL-ME-MP, Fort Monmouth, NJ07703-5000. A reply will be furnished to you.

CHAPTER 1.Section I

II.

CHAPTER 2.Section I.

Sect ion I I .

INTRODUCTIONGeneralScope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .Index of Technical Publications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance forms, records and reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Administrative storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Destruction of Army electronics material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .Reporting equipment improvement recommendations (EAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Description and DataDescription . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . .Tabulated data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUNCTIONING OF EQUIPMENTBlock Diagram AnalysisGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Scope of Figure FO-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ac-dc rectifier circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400 Hz sensing circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .Dc-to-dc converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115/230 Vac switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14V/28V switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control circuit power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Output rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . .Output voltage regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Output voltage control/adjust circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Output current control/adjust circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Monitoring output voltage and output current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Protective circuitry and reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Detailed Circuit AnalysisScope of Figure FO-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .Input power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Relays A1K1 and A1K3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paragraph

1-11-21-31-41-51-61-7

1-81-9

2-12-22-32-42-52-62-72-82-92-102-112-122-132-142-15

2-162-172-18

Change 1

Page

1-11-31-31-31-31-31-3

1-31-6

2-12-12-12-12-12-12-12-12-22-22-22-22-22-22-2

2-22-22-3

i

TM 11-6130-356-34


II.

III.

IV.

V.


II.

APPENDIX A.B.

Section I.

II.

Dc-to-dc converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . .Converter rectifier and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Output voltage regulator and regulator control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Current limit sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Voltage throw-off (CHARGE OVER). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reverse polarity protection.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paragraph

DIRECT SUPPORT MAINTENANCE INSTRUCTIONSGeneralDirect Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Use of test equipment for measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Voltageandresist.ante measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Waveform diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tools and EquipmentGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. . . . . . .. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Test equipment required . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TroubleshootingGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting procddures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance of PP-6148/UGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjustment/alinement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General parts replacement tenchniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal, disassembly and reassembly of cover assembly Al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal, disassembly and reassembly of control circuit card assembly A2 . . . . . . . . . . . . . . . . . . . .Removal, disassembly and reassemblyof resistor plateassembly A3 . . . . . . . . . . . . . . . . . . . . . .Disassembly and reassembly of chassis mounted components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Direct Support Testing ProceduresGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Modification work orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Physical tests and inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Voltage tests, input and output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Recovery timetest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..Ripple voltage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overload protection and current limiting test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery discharging/charging test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL SUPPORT MAINTENANCE INSTRUCTIONSGeneralGeneral Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance of PP-6148/UGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disassembly instructions . . . . . . . . . . . . . . . . . . .Removal, disassembly and reassembly of converter circuit card assembly A1A1 and

control circuit card assembly A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REFERENCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . .EXPENDABLE SUPPLIES AND MATERIALS LISTIntroductionScope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Explanation of columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Special information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Expendable Supplies and Materiels List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-192-202-212-222-232-242-25

3-13-23-33-4

3-63-6

3-73-8

3-93-103-113-123-133-143-153-163-17

3-183-193-203-213-223-233-243-25

4-1

4-24-34-4

4-5

B-1B-2B-3

Page

2-32-32-32-32-32-42-4

3-13-13-13-5

3-103-10

3-103-10

3-143-143-163-153-153-173-173-173-18

3-223-223-223-233-273-303-313-33

4-1

4-14-14-1

4-1

A-1

B-1B-1B-1

i i

TM 11-6130-356-34

Figure1-11-11-21-23-13-13-13-23-23-23-23-33-43-53-53-63-73-83-93-104-14-2FO-1FO-2FO-3FO-3FO-3

Number3-13-23-33-43-53-6

LIST OF ILLUSTRATIONSTitle

Power Supply PP-6148/U and Battery Charger Cable Assembly (Sheet l of 2) . . . . . . . . . . . . . . . . . . . . . . . . .Power Supply PP-6148/U and Battery Charger Cable Assembly (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . .PP-6148/U Internal Configuration (Sheet l of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PP-6148/U InternalConfiguration (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Voltage and Resiatance Diagram(Sheet l of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Voltage and Resistance Diagram (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Voltage and Reaistance Diagram(Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Waveform Diagram (Sheet l of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Waveform Diagram (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Waveform Diagram (Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Waveform Diagram (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover Assembly Al, Parts Location Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Resistor Plate Assembly A3, Parts Location Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PP-6148/U Chassis Mounted Components, Parts Location Diagram (Sheet l of 2) . . . . . . . . . . . . . . . . . .PP-6148/U Chassis MountedCompnents. Parts Location Diagram (Sheet 2 of 2) . . . . . . . . . . . . . . . . .Basic Test Setup Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Recovery Time Test Setup Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overload Protection and Current Limiting Test Setup Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery Discharging/Charging Test Setup Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery Discharging Test Setup Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Converter Circuit Card Assembly (A1A1), Parts Location Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Circuit Card Assembly (A2) Parts Location Diagram . . . . . . . . . . . . . . . . . . . Color Code Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . .Power Supply PP-6148/U Functional Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Supply PP-6148/U Schematic Diagram (Sheet l of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Supply PP-6148/U Schematic Diagram (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Supply PP-6148/U Schematic Diagram (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

L I S T O F T A B L E STitle

Integrated Circuit and SCR Dc Voltage Measurement Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PP-6148/U Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover Assembly A1 TroubIeshootingChart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Converter Circuit Card Assembly A1A1 Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Circuit Card Assembly A2 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Resistor Plate Assembly A3 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Page1-21-2.11-41-53-23-33-43-63-73-83-93-163-183-193-203-233-283-323-343-354-24-3

All fold-outillustrationsare locatedin back ofmanual.

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TM 11-6130-356-34

CHAPTER 1

INTRODUCTION

Section I.

1-1. ScopeThis manual describes the lightweight batterycharger Power Supply PP-6148/U (fig. 1-1) andcovers its functions and maintenance at the directsupport and general support levels. This manualincludes functional descriptions, adjustments,testing, troubleshooting and repair of batterycharger Power Supply PP-6148/U. Throughout this

GENERAL

manual, battery charger Power Supply PP-6148/Uis commonly referred to as the PP-6148/U. Ap-pendix A contains a list of publications applicable tothe PP-6148/U. Appendix B consists of the Ex-pendable Supplies and Materials List applicable tothe direct support and general support levels ofmaintenance. The Repair Parts and Special ToolsList is located in TM 11-6130-356-34P.

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Figure 1-1(1). Power Supply PP-61481U and Battery Charger Cable Assembly (Sheet 1 of 2)

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Figure 1-1(2). Power Supply PP-6148/U and Battery C’hargcr Cable Assemby (Sheet 2 of 2)

Change 1 1-2.1/(1-2.2 blank)

TM 11-6130-356-34

1-2. Consolidated Index of Army Publications andBlank Forms

Refer to the latest issue of DA Pam 25-30 to determinewhether there are new editions, changes, or additionalpublications pertaining to the equipment.

1-3. Maintenance Forms, Records, and Reports

a. Reports of Maintenance and UnsatisfactoryEquipment. Department of the Army forms and pro-cedures used for equipment maintenance will be thoseprescribed by DA Pam 738-750, as contained inMaintenance Management Update.

b. Report of Packaging and Handling Deficiencies.Fill out and forward SF 364 (Report of Discrepancy(ROD)) as prescribed in AR 735-1l-2/DLAR 4140.55/NAVMATINST 4355.73B/AFR 400-54\MC04430.3H.

c. Discrepancy in Shipment Report (DISREP) (SF361). Fill out and forward Discrepancy In ShipmentReport (DISREP) (SF 361) as prescribed in AR 55-38/NAVSUPINST 4610 .33C/AFR 75-18/MCOP461O.19D/DLAR 4500.15.

1-4. Administrative Storage

Before placing this instrument in storage, its completeoperability must be verified and all deficiencies cor-rected by accomplishing the performance checks andadjustment procedures, and maintenance, as prescribed

in chapters 4 and 5. Be sure that the ac power cable is inits storage location in the top cover panel, and that thecover is properly fastened on the top panel. Secureadapter cable to unit. Place the equipment in limitedstorage, i.e., organizational storage room. Protectequipment from dust, humidity, and extremetemperature changes.

1-5. Destruction of Army Electronics Materiel

Destruction of Army Electronics Materiel to preventenemy use shall be as prescribed in TM 750-244-2.

1-6. Calibration

This equipment is to be calibrated in accordance withTB 43-180, Calibration Requirements for theMaintenance of Army Materiel.

1-7. Reporting Equipment ImprovementRecommendations (EIR)

If your equipment needs improvement, let us know.Send us an EIR. You, the user, are the only onewho can tell us what you don’t like about thedesign. Put it on an SF 368 (Quality Deficiency Report).Mail it to Commander, US Army Communications-Electronics Command and Fort Monmouth, ATTN:AMSEL-PA-MA-D, Fort Monmouth, New Jersey07703-5000. We’ll send you a reply.

Section Il. DESCRIPTION AND DATA

1-8. Description description of the internal configuration of the

A general description of the make-up of thePP-6148/U (fig. 1-2) is provided in the following

PP-1648/U is contained in ‘I’M 11-6130-356-12. Aparagraph.

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Figure 1-2(1). PP-6148/U Internal Configuration (Sheet 1 of 2).

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Figure 1-2(2). PP-6148/U Internal Configuration (Sheet 2 of 2)

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a. The PP-6148/U is comprised of three majorassemblies: (1) cover assembly Al, (2) control circuitcard assembly A2, and (3) resistor plate assemblyA3. Cover assembly Al is assembled to the chassisof the PP-6148/U with captive hardware. A gasket,recessed in the flange of the chassis, seals the sur-faces of the chassis and cover assembly Al.

b. Cover assembly Al contains heat producingcomponents mounted directly to it. These com-ponents are the saturable core feedback transformerA1T1, converter power transformer A1T2, rectifierA1CR1, power and filter switching relays A1K1through A1K3, switching transistors A1Q1 throughA1Q4, and converter circuit card assembly AlAl.

c. Control circuit card assembly A2 is mounted onstandoffs to the inside of the right side of thePP-6148/U chassis. Control circuit card assemblyAZ contains components of the input frequency sen-sing, output regulation and control, and associatedauxiliary power supply circuits.

d. Additional heat producing components aremounted to the inside of the PP-6148/U chassisheat sink. These components include filtercapacitors and inductors, the series pass elements ofthe output regulator, and resistor plate assemblyA3. Resistor plate assembly A3 contains the currentrange limiting resistors A3R1 through A3R6.

e. All components of the PP-6148/U are securedto either cover assembly A1, the top panel, or to theinside of the chassis. Service access to all com-ponents is accomplished by removing cover assem-bly Al. When removed, electrical connection bet-ween cover assembly Al and the power supplychassis is maintained through a multiwire harnesswith enough service length to enable on-line main-tenance.

1-9. Tabulated Data

For a listing of technical characteristics and alisting of components supplied, refer to TM11-6130-356-12.

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CHAPTER 2

FUNCTIONING OF EQUIPMENT

Section I. BLOCK DIAGRAM ANALYSIS

2-1. General

This chapter describes the theory of operation of thePP-6148/U. These descriptions are presented on afunctional block and detailed circuit analysis leveland are supported by the foldout diagrams (fig.FO-1, FO-2, and FO-3) located at the rear of thismanual. Figures FO-2 and FO-3 illustrate the func-tional block and detailed schematic diagrams,respectively. Figure FO-1 explains the color codingsystem used to identify circuit component valuesand should be referred to when performing repairprocedures.

2-2. Scope of Figure FO-2

The following paragraphs describe the PP-6148/Uon a functional block level with reference to theblock diagram, figure FO-2. The PP-6148/U is com-prised of those circuit blocks illustrated on figureFO-2.

2-3. General Function

The PP-6148/U provides a regulated 12 to 16 V dcor 24 to 32 V dc output required to operate militarycommunications equipment such as Radio SetAN/PRC-70 or to charge an external battery. ThePP-6148/U maintains a constant output voltageregardless of variations in ac line voltage within+15 and – 10 percent. The PP-6148/U maintains aconstant output voltage regardless of outputcurrent until its current limiting setting is reached,above which, output current is maintained constantand output voltage decreases proportionately withthe resistance of the load. The operating power forthe PP-6148/U is 115 or 230 V ac at a frequency of50, 60, or 400 Hz ± 5 percent.

2-4. Ac-Dc Rectifier Circuit

The ac input voltage from AC INPUT connector J1is applied through AC ON/OFF circuit breaker CB1,to the full wave bridge rectifier CR1, part of theac-dc rectifier filter. The dc output of primary rec-tifier CR1 is filtered by inductor L1, part of the ac-dc rectifier filter, and capacitors Cl through C4 andprovides a dc prime power source for the dc-to-dcconverter circuits.

2-5. 400 Hz Sensing Circuit

The 400 Hz sensing circuit consists of a high passfilter network that activates relay A1K2 when thePP-6148/U is operated from a 400 Hz source. Whenactivated, relay A1K2 shorts out filter inductor L1in the ac-dc rectifier filter. The shorting of inductorLI is required to eliminate excessive voltage dropacross the inductor to 400 Hz, and maintain anadequate dc power level to the dc-to-dc converter forinput line variations.

2-6. Dc-to-Dc Converter

The dc-to-dc converter consists of high frequencyconverter switching transistors A1Q1, A 1 Q 2A1Q3, and A1Q4, power transformer A1T2, andsaturable core feedback transformer A1T1, followedby full wave bridge rectifier A1CR1, currentlimiting resistor R6, shorting relay P/C) K1, andfilter capacitor C5. This circuitry comprises a self-oscillating high frequency power converter by virtueof the saturating characteristics of feedback trans-former A1T1. These transformer characteristicsestablish the oscillating frequency and providealternating base drive pulses to the switching tran-sistors.

2-7. 115/230 V ac Switching

The 115/230 V ac switching circuit (imcluding tran-sistors A1A1Q1 through A1A1Q4 is a level-sensingcircuit that activates relays A1K1 and A1K3 whenthe power supply is operated from a 115 V ac powersource. When not activated, the contact con-figuration of relay A1K1 places the dual primarywindings of power transformer A1T2 in series for230 V ac operation. When activated, the contactconfiguration of relay A1K1 places the dual primarywindings of power transformer A1T2 in parallel for115 V ac operation. Similarly, relay A1K3 switchesthe tapped feedback winding to equalize switchingcircuit drive.

2-8. 14V/28V SwitchingThe secondary winding of power transformer A1T2is center-tapped to provide output level switchingfor 14 V dc and 28 V dc output requirements. When

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TM 11-6130-356-34

set in the 28V position VOLT SELECT 14V/28Vswitch S1, located on the top panel, connects the en-tire secondary winding to the output regulator cir-cuits, and connects one-half the secondary windingto these circuits when VOLT SELECT 14V/28Vswitch S1 is set in the 14V position.

2-9. Control Circuit Power Supply

The control circuit power supply provides regulateddc power to critical control circuits and foroperation of 28 V dc relays. The control circuitpower supply uses the full secondary winding ofpower transformer A1T2 as its ac power source.This ac power is rectified by the full wave bridge rec-tifier A2CR1 through A2CR4, filtered, andregulated by zener-controlled, chassis-mountedtransistor Q3.

2-10. Output Rectifier

The ac power output of power transformer AlT2 is.rectified by full wave rectifier bridge AlCR1 andfaltered by capacitor C5 to provide the dc powersource for the output voltage regulator. At initialturn-on, current limiting resistor R6 is placed bet-ween rectifier bridge AlCR1 and filter capacitor C5to limit the charging current. The resistor is shortedout by shorting relay P/O K1 after a short timedelay period.

2-11. Output Voltage Regulator

The output voltage regulator is a high frequencyvoltage switching regulator that is pulse width andfrequency controlled by the regulator control A2U2.Two series pass transistors, Q1 and Q2, are used inparallel to accommodate the output voltage andcurrent requirements and to distribute heat losseson the heat sink surface. The series pass transistorsare followed by a filtering network consisting of anenergy storing inductor, L2, and filter capacitors C6and C7. A shunt diode, CR2, permits current con-tinuation when transistors Q1 and Q2 are switchedoff.

Section Il. DETAIL ED2-16. Scope of Figure FO-3

The following paragraphs describe the PP-6148/Uon a detailed level with reference to the schematicdiagram, figure FO-3. Each block described in Sec-tion I is expanded in the following discussion.

2-17. Input Power

The ac input voltage is applied to AC INPUT con-nector J1. This voltage, which is RFI-suppresed by

2-12. Output Voltage Control/Adjust Circuits

The output voltage control/adjust circuits includeresistor divider networks with potentiometers fortop panel control (VOLTAGE ADJUST Rl) andvoltage throw-off (CHARGE OVER) level ad-justments (A2R26 and A2R33). VOLT SELECTSWITCH S1 reconnects pertinent control andmonitor components according to the selected 14Vor 28V position.

2-13. Output Current Control/Adjust Circuits

The output current limit is selected by CURRENTRANGE switch S2 and the load current is sensedacross the current limit sense selected precisionresistor(s) A3R1 through A3R6. The current con-trol/adjust circuit consists of A2U1 and CURRENTADJUST (FINE) potentiometer R2. Within theselected range (to 8 amperes), the limit is varied bythe CURRENT ADJUST (FINE) potentiometer R2and controlled through A2U1's effect on the swit-thing regulator control A2U2.

2-14. Monitoring Output Voltage and OutputCurrent

Dc output voltage, available when DC ON/OFF cir-cuit breaker CB2 is in the ON position, is normallymonitored on OUTPUT meter M1, and outputcurrent can be selected for meter indication by theuse of VOLTS/AMPS switch S4. S4 is a spring-loaded switch, which reverts to the VOLTS positionupon release. DC ON/OFF circuit breaker CB2 alsofunctions as an overload protection device.

2-15. Protective Circuitry and Reset

Both the voltage throw-off (CHARGE OVER) andthe battery reverse polarity protection circuits func-tion by de-energizing output relay K1, which discon-nects the power supply negative output lead from dcoutput connector J2. Relay A2K1 functions to lightCHARGE OVER lamp DS1, while CHARGERESET switch S3 is used to restore the circuit tothe operational mode.

CIRCUIT ANALYSISEMI filters FL1 and FL2, is applied to AC ON/OFFcircuit breaker CB1. This circuit breaker limits inputcurrent to 7.5 amperes for an extended period andwill withstand 12 ampere surges for periods up to 300milliseconds. On serial No’s 155A and up, bleederresistors R8 through R11 are provided as a safetymeasure to discharge filters FL1 and FL2 after acpower is removed from the PP45148/U. When ACON/OFF circuit breaker CB1 is set to the ON posi-tion, the ac input voltage is applied to the ac-dcrectifier filter network. This network is comprised ofdiode bridge CR1, capacitors Cl through C4, and

2-2 Change 1

TM 11-6130-356-34

Diode bridge CR1 provides full-wave rectified dc tofilter capacitors Cl through C4 and inductor L1.This inductor corrects the power supply input powerfactor for 50 or 60 Hz operation. The full-wave rec-tified and filtered dc from the ac-dc rectifier filter isapplied to the 115/230 Vac switching and de-to-deconverter circuits.

2-18. Relays A1K1 and A1K3

Transistors Q1 through Q4 (on converter circuitcard assembly AlAl) and their associated circuitsfunction to energize relay A1K1, which reconnectsthe primary windings of power transformer A1T2for operation from a 115 V ac input line. RelayA1K3, similarly, operates and functions to equalizedrive to feedback transformer AIT1. With 230 V acinput, the base-to-emitter bias keeps transistorsA1A1Q4 cut off and relays A1K1 and A1K3 de-energized.

2-19. Dc-to-DC Converter

The ac-dc rectifier filter output operates a dc-to-dcconverter network consisting of panel-mountedpower transistors A1Q1 through A1Q4, com-ponents on converter circuit card assembly, panel-mounted transformers A1T1 andhAlT2, diodebridge A1CR1, and chassis-mounted capacitor C5.On cover assembly Al, when the output of the ac-dcrectifier filter first rises, transistors A1Q1 andA1Q4 start to conduct, and current flows throughthe primary winding of transformer A1T2 from ter-minal 1 to terminal 4. Feedback from secondary win-ding (terminals 5, 6 and 7) of transformer A1T2 tothe primary winding of transformer A1T1 (ter-minals 1 and 2), and so to its secondary windings(terminals 9 and 10 and terminals 3 and 4), quicklydrives transistors A1Q1 and A1Q4 to full con-duction. The core flux density of transformer A1T1rises to saturation, at which time the transformeraction reverses, cutting off transistors AlAl andA1Q4 and turning on transistors A1Q2 and A1Q3.Current now flows through the primary winding oftransformer A1T2 from terminal 4 to terminal 1.Current flow is thus reversed, until transformer coresaturation results, when the sequence is again rever-sed. These alterations occur at approximately 3000cycles per second.

2-20. Converter Rectifier and Filter

With the initial surge limited by resistor R6, theresulting square wave output on A1T2 secondarywindings (terminals 8 to 9 or 8 to 10) is rectified bydiode bridge A1CR1 and faltered capacitor C5. Thisconverter output dc is then applied to the outputvoltage regulator, regulator control, and associatedcircuits.

2-21. Output Voltage Regulator and RegulatorControl

The output voltage regulator consists of two seriespass transistors in parallel, chassis-mounted trans-istors Q1 and Q2, circuit elements on control circuitcard assembly A2, and storage inductor L2. The toppanel VOLTAGE ADJUST control R1 andCURRENT ADJUST (FINE) control R2 providesvernier adjustment of these control circuits. As thede-de converter output voltage starts to rise fromzero, the regulator control, consisting of integratedcircuit A2U2 (functioning as a Schmitt trigger) andthe drive transistor A2Q4 and A2Q5, maintains theseries pass elements of the output voltage regulatorin a full conduction state. Load current is throughstorage inductor L2. When the voltage exceeds thetrigger level of Schmitt trigger A2U2, it changesstate and the series pass elements are turned off.The magnetic field of inductor L2 collapses, main-taining current flow until the output voltage fallsbelow the trigger level of Schmitt trigger A2U2. Theseries pass elements are again saturated. Switchingtransition periods are a few hundred nanoseconds,power losses are minimized, and relatively high ef-ficiency is achieved. Output voltage adjustmentwithin the selected 14V or 28V range is obtained bychanging the voltage input to Schmitt triggerA2U2. Fine adjustment is by means of VOLTAGEADJUST control R1 on the top panel.

2-22. Current Limit Sense

The current from the output voltage regulator issensed in a series resistance network connected inthe positive dc output line. The voltage drop isproportion to the output current within a selectedrange, and part of it is applied through integratedcircuit amplifier A2U1 to the integrated circuit Sch-mitt trigger A2U2 to effect a reduction in outputvoltage when the output current reaches the selec-ted and adjusted value. The output current limitrange is selected by switching the precision seriesresistors (A3R1 through A3R6) according to theposition of the CURRENT RANGE switch S2. Inthe 10 position the current limit is fixed at 10 am-peres. Within the selected (1, 2, 4, or 8) current limitrange, vernier adjustment is provided by theCURRENT ADJUST (FINE) control R2 connected(in combination with resistor A2R42) across thecurrent limiting series resistor in use. The ad-justable contact of CURRENT ADJUST (FINE)control R2 provides the finely adjusted limitingpotential to the integrated circuits.

2-23. Overload Protection

Additional protection from electrical damage due tooverload is provided by the DC ON/OFF circuit

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breaker CB2 in the dc output circuit. It is a fast-acting, trip-free, hydraulic-magnetic type which ser-ves the additional function of a switch. The overloadtrip function will operate even if the toggle lever ismanually held in the ON position. The DC ON/OFFcircuit breaker CB2 is a single-pole unit rated at 11.2amperes, and will trip instantaneously on severeoverloads.

2-24. Voltage Throw-Off (CHARGE OVER)

The output voltage level is additionally applied to asensing and control network on control circuit cardassembly A2, for use in effecting output disconnectat pre-set limits. Components selectively connectedby the positioning of the VOLT SELECT 14 V/28bvswitch S1 provide for automatic disconnect of the dcoutput line at a level of 16.0 to 16.4 V dc in the 14Vposition, and 32.0 to 32.8 V dc in the 28V position.These levels are precisely set during final factorytests by the use of internal adjustment (poten-tiometer A2R33 for the 14V range and poten-tiometer A2R26 for the 28V range). When the out-put voltage reaches the pertinent voltage limit, thecontrol and drive circuits associated with tramsisters A2Q6 through A2Q8 operate to gate on tran-sistor A2Q9 and energize output relay A2K1 in thevoltage throw-off circuit. Normally-closed contactsof output relay A2K1 open to release chassis-mounted K1, which in turn opens the dc outputnegative ( — ) line, disconnecting the battery fromthe charging circuits. The LC network in the emittercircuit of transistor A2Q8 prevents operation of thecutoff relay as a function of transients. A normally-open contact of A2K1 closes to light the CHARGEOVER lamp DS1. Momentary operation ofCHARGE RESET SWITCH S3 restores the circuitto the operational mode.

2-25. Reverse Polarity Protection (SerialNos 1A Thru 206A)

Circuits on control circuit card assembly A2, inassociation with chassis-mounted relay K1, preventdamage to the power supply conversion and controlcircuits in the event that the battery for charging isinadvertently connected with the polarity reversed.

In normal operation, with the battery properly con-nected, the gate of SCR A2Q11 is back-biased,preventing operation of relay A2K2, and relay K1 isenergized through normally-closed contacts ofrelays A2K1 and A2K2 when control circuit voltagehas gated on SCR A2Q10 to provide a return pathfor the coil of relay K1. With relay K1 energized, itsnormally-open contacts connect the dc outputnegative (–) line to dc output connector J2. If a bat-tery is connected with polarity reversed, the gate ofSCR A2Q11 is forward-biased, and relay A2K2 canbe energized. If the battery, so connected, has avoltage potential and current capability that wouldinflict damage on the power supply conversion andcontrol circuits, relay A2K2 will be energized, itsnormally-closed contacts are open, relay K1 cannotbe energized, and the power supply negative (–) dcoutput line remains open between the battery andthe power supply conversion and control circuits.

2-26. Reverse Polarity Protection (SerialNos 207A and Up)

Circuits on control circuit card assembly A2, inassociation with chassis-mounted relay K1, preventdamage to the power supply conversion and controlcircuits in the event that the battery for charging isinadvertently connected with the polarity reversed,In normal operation, with the battery properly con-nected, diode CR7 is back-biased, preventing opera-tion of relay A2K2, and relay K1 is energized throughnormally-closed contacts of relays A2K1 and A2K2when control circuit voltage has gated on SCR A2Q10to provide a return path for the coil of relay K1. Withrelay K1 energized, its normally-open contacts con-nect the dc output negative (—) line to dc outputconnector J2. If a battery is connected with polarityreversed, diode CR7 is forward-biased, and relayA2K2 can be energized. If the battery, so connected,has a voltage potential and current capability thatwould inflict damage on the power supply conversionand control circuits, relay A2K2 will be energized, itsnormally-closed contacts are open, relay K1 cannotbe energized, and the power supply negative (—) dcoutput line remains open between the battery andthe power supply conversion and control circuits.

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TM 11-6130-356-34

DIRECT SUPPORT

CHAPTER 3

MAINTENANCE INSTRUCTIONS

Section I. GENERAL

3-1. Direct Support

Maintenance at the direct support level includes allprocedures outlined for operator and organizationalmaintenance, and additional procedures whichrequire test equipment and/or skills not available atthe operator and organizational level. These ad-ditional procedures include all the required testing,troubleshooting and maintenance of the PP-6148/Uat the direct support level. Direct support maint-enance restricts the converter circuit card assem-bly (AlA1) and the control circuit card assembly(A2) to testing and replacement only. Paragraphs3-2 through 3-25 provide these addit ionalprocedures for maintenance of the PP-6148/U at thedirect support level.

3-2. Use of Test Equipment for Measurements

WARNINGHigh voltages and currents exists in thisequipment. Serious injury or death mayresult from contact with the output ter-minals or internal circuitry. To avoid in-jury, be sure that the AC ON/OFF circuitbreaker and the DC ON/OFF circuitbreaker are set to OFF before connectingor disconnecting any external equipment.On serial numbers 1A through 154A,momentarily turn the AC ON–OFF circuitbreaker first to the ON position, and thento the OFF position after disconnectingAC power input cable assembly W1. Thisaction will discharge any voltage presentat the terminals o f A C I N P U TCONNECTOR Jl, and is required to avoidelectrical shock hazard.

directions governing the use of the test equipmentrequired to maintain the PP-6148/U.

CAUTIONDo not make any resistance measure-ments on the PP-6148/U other than thosespecified, or while the ac power cable isconnected.

b. Voltage Measurement Precautions. Whenmeasuring voltages, use tape or sleeving to insulatethe entire test probe, except for the extreme tip. Amomentary short circuit can damage a transistor.(For example, if the bias resistor of a transistor isshorted out by touching both its emitter and basewith the test probe, excessive current between theemitter and the base would damage the transistor.)Use the voltage and resistance diagram (fig. 3-1), tofind the normal readings, and compare them withthe readings taken.

3-3. Voltage and Resistance Measurements

The voltage and resistance measurements for alltransistors in the PP-6148/U are indicated in thevoltage and resistance diagram (fig. 3-1). Table 3-1provides the dc voltage measurements for all in-tegrated circuits and silicon control rectifiers(SCR’s). Before making measurements, determinewhether faulty operation is due to one of the com-ponents listed in figure 3-1 or table 3-1. To do this,follow the troubleshooting procedures (section III)and make the checks given in the applicable chart.Do not use resistance measurements as the solebasis for discarding any transistor as defective.Because of tolerances during manufacture, resistan-ces of identical transistors may vary from the chartvalues.

a. Resistance Measurement Precautions. ThePP-6148/U is transistorized. Strictly adhere to the

Change 1 3-1

TM 11-6130-356-34

NOTES1.

2.

3.

4.

ALL VOLTAGE MEASUREMENTS ARE FROM DESIGNATED TERMINALTO CHASSIS USING SEMICONDUCTOR DEVICE TEST SETTS-1836( )/U, NO SIGNAL CONDITIONS.MAKE RESISTANCE MEASUREMENTS BETWEEN INDICATED TERMINALS WITHSEMICONDUCTOR DEVICE TEST SET TS-1836( )/U.WHERE TWO RESISTANCE READINGS BETWEEN TERMINALSARE GIVEN, THE TOP READING IS THE RESISTANCEMEASURED WITH THE POSITIVE OHMMETER LEADCONNECTED TO THE BASE, THE BOTTOM READING IS THERESISTANCE MEASURED WITH THE NEGATIVE OHMMETER LEAD CONNECTEDTO THE BASE. BE SURE TO CHECK THE ACTUAL POLARITY OF THE OHMMETERLEADS BEFORE MAKING MEASUREMENTS.SEE WAVEFORM DIAGRAM, FIGURE 3-2.

Figure 3-1(1). Voltage and ResistanceDiagram (Sheet l of 9).

3-2 Change 1

TM 11-6130-356-34

Figure 3-1(2) Voltage and Resistance Diagram (Sheet 2 of 3).

Change 1 3-3

TM 11-6130-356-34

Figure 3-1(3). Voltage and Resistance Diagram (Sheet 3 of 3).

3-4

TM 11-6130-356-34

Preliminary Instructions for Table 3-1:1. PP-6148/U connected to a 115 V ac, 60 Hz source.2. PP-6148/U set for 28 V dc as indicated on the OUTPUT meter.3. No output load.4. AC and DC ON/OFF circuit breakers set to ON.5. Oscilloscope internal sync used as applicable.6. All readings are+ V dc measured to ground (anode VR3 or VR4 as indicated).

a. Table 3-1. Integrated Circuit and SCR Dc Voltage Measurement Chart

Integrated Circuit

Ref des/part number

A2U1/SM-C-595345(GND VR3)

A2U2/SM-C-596345(GND VR4)

3-4. Waveform Diagram

Measurements

Pin12,3,466789

10

123466

7,89

10

28Not usedGround

8Not used

3128.627.6

Not used7.37.37.3

Ground30

3729

Not used

Where a voltage meter level alone gives inadequateindication of circuit condition, the general nature ofoscilloscope waveforms as shown in figure 3-2should be observed. These waveforms are obtainedwith the PP-6148/U setup as follows:

a. PP-6148/U connected to a 115 V ac, 60 Hzsource.

Ref des/part number

A2Q3/2N2324(GND VR3)

A2Q9/2N2324(GND VR4)

A2Q1O/VN67AB(GND VR3)

A2Q11/2N2324(GND VR4)

TerminalGateCathodeAnode

GateCathodeAnode

GateCathodeAnode

GateCathode

Anode

Readingo0

31

00

28

0.7500.8

12.612

28

b. PP-6148/U set for 28 V dc, as indicated on theOUTPUT meter.

c. Approcimately 5.5 amperes output load.d. AC and DC ON/OFF circuit breakers set to

ON.e. Oscilloscope internal sync used as applicable.

Change 1 3-5

TM 11-6130-356-34

(A)WAVEFORM AT EMITTER AND BASE0F QI AND Q2 AND collector OFA204 TO DC OUTPUT CONNECTOR J2(-) (J2-I OR KI-A2)

(C)WAVEFORM AT COLLECTOR OF Q3 T0DC OUTPUT CONNECTORJ2 (-) (J2-I OR KI-A2)

(e)WAVEFORM AT COLLECTOR OF QI ANO Q2AND EMITTER OF A2Q4 TO DC OUTPUTCONNECTOR J2 (-) (J2-I OR KI-A2)

(D)WAVEFORM AT EMITTER AND BASEOF AIQI AND AIQ3, AND COLLECTOR0F AIQ2 AND AIQ4 TO GROUND

3-6

Figure 3-2(1). Waveform Diagram (Sheet 1 of 4).

TM 11-6130-356-34

(E)

WAVEFORM AT COLLECTOR OF AIQIAND AIQ3 TO GROUND

(G)

WAVEFORM AT BASE OF AIQ2 ANDAIQ44 TO GROUND

(F)

WAVEFORM AT EMITTER OFAIQ2 AND AIQ4 To GROUND

( H )

WAVEFORM AT EMITTER,BASE,AND COLLECTOR OF AIAIQI ANDBASE OF AIAIQ3 TO GROUND

FIgure 3-2(2). Waveform Diagram (Sheet 2 of 4).

3-7

TM 11-6130-356-34

(1)WAVEFORM AT EMITTER AND BASEOF AIAIQ2 TO GROUND

(K)

WAVEFORM AT EMITTER OF AIA103TO GROUND

(J)WAVEFORM AT COLLECTOR OF

(L)

WAVEFORM AT COLLECTOR OFAIAIQ3 TO GROUND

3-8


TM 11-6130-356-34

(M)WAVEFORM AT EMITTER OF AIAIQ4TO GROUND

(O)WAVEFORM AT BASE OF A2Q4 ANDCOLLECTOR OF A2Q5 TO DC OUTPUTCONNECTOR J2 (-) (J2-I OR KI-A2)

(N)WAVEFORM AT COLLECTOR OFAIAIQ4 TO GROUND

(P)WAVEFORM AT EMITTER AND BASEOF A2Q5 TO DC OUTPUTCONNECTOR J2(-) (J2-I OR KI-A2)


3-9

TM 11-6130-356-34

Section Il. TOOLS AND EQUIPMENT

3-5. General properly calibrated test equipment items of theRefer to the repair parts and special tools list (RP- following types (or suitable substitutes) areSTL), TM 11-6130-356-34P, and the maintenance required:allocation chart, appendix D, TM 11-6130-356-12, a.for tools and equipment required to maintain the b .PP-6148/U.

d.3-6. Test Equipment Required

To perform maintenance tasks of this section, f.g.

c.

Multimeter AN/USM-223/U,Oscilloscope AN/USM-281.Test Set, Semiconductor Device TS-1836( )/U.Tool Kit, Electronic Equipment TK-105/G.Transformer, Variable Power TF-510/U.Voltmeter, Electronic ME-202( )/U.Dummy Load, Electrical DA-638/U.

e.

Section I I I . TROUBLESHOOTING

3-7. General

The first step in servicing a defective PP-6148/U isto localize the fault to a defective stage or circuitresponsible for the abnormal condition. The secondstep is to isolate the fault to a specific defective partor parts. In localizing or isolating a fault, thepossibility of intermittent troubles should not beoverlooked. If present, this type of trouble may bemade to reappear by tapping or jarring the equip-ment. Check all internal wiring for poor solder con-nections or loose terminals if intermittent troublesare evident.

a. Localization. The defective stage or circuit canoften be located by one of the following methods:

(1) Top panel OUTPUT meter indications (para3-8).

(2) Visual inspection, the purpose of which is tolocalize faults without testing or measuring circuitvoltages or resistances. Through this inspection, therepair technician frequently can discover troubles,such as burned resistors or arcing transformer, ordetermine the circuit in which the trouble exists.This inspection is valuable in avoiding additionaldamage which might occur through improper ser-vicing methods, and in preventing future failures.

b. Isolation. Most defective parts must beisolated by checking voltages and resistances. Referto paragraphs 3-2, 3-3, and 3-4 for voltage andresistance measurement procedures. In addition,the indications listed in the troubleshooting charts(table 3-2 thru 3-6) will aid in isolating the trouble.

3-8. Troubleshooting Procedures

Refer to the troubleshooting charts (tables 3-2 thru3-6) for step-by-step procedures for systematictroubleshooting and fault isolation or localization ofthe rnalfunctioning PP-6148/U subassemblies orcompon rots. In addition, using only the OUTPUT

meter, CHARGE OVER indicator, and operatorcontrols, and by carefully observing the results ob-tained while performing the operational checks ofparagraph 3-4, TM 11-6130-356-12, a preliminarybut effective analysis of fault location can be madeof faults occurring from the voltage switchingregulator to the output. (Refer to chapter 2 andfigures FO-1, FO-2 and FO-3 for circuit descrip-tions, related component reference designations,and explanation of component color codes.)

a. When the input power source and output loadhave been verified as normal, and with both AC andDC circuit breakers in the ON position, if there is noOUTPUT meter indication in either 14V or 28VVOLT SELECT switch position, or in anyCURRENT RANGE switch position while holdingthe VOLTS/AMPS switch at AMPS, the fault(s)could be in the regulator, converter, or input powercircuits. However, in paragraph 3-4b, TM11-6130-356-12, if the CHARGE OVER indicatordoes light, the fault location is in the meter, its swit-ch(es) or connections.

b. In the absence of meter indications as in subparagraph a above, if the CHARGE OVER in-dicator lights in only one VOLT SELECT switchposition (14V or 28 V), correction of any meter cir-cuit faugts should be followed by attention to theCHARGE OVER voltage cutoff level adjustmentprocedure (para 3-10) for the VOLT SELECT swit-ch position in which the CHARGE OVER indicatordid not light. If associated OUTPUT meter in-dications are subsequently observed to be normal,but the CHARGE OVER voltage cutoff level can-not be properly adjusted for one VOLT SELECT —switch positiion, the components and connectionspeculiar to that adjusting network are the probablefault location(s).

c. In circumstances where part of the OUTPUT

3-10

meter indications (or responses) are normal, andothers are not, the particular positions of the swit-ches or the operation of control(s) associated withabnormal indications will reflect limited areas ofprobable fault location

(1) Abnormal indication observed only in oneVOLT’ SELECT switch positiion effectivelyeliminate input power/switching and H-switch con-version circuits from fault consideration. Faultlocation effort can be confined to circuits, com-ponents, and Connections, starting at the secondaryof converter output transformer A1T2 through thelimited circuit elements associated peculiarly withthe pertinent switch positiin. It can be expectedthat consideration of all details of the abnormal in-dications will further limit the probable area offault.

(2) If OUTPUT meter indications are normal(on both VOLT SELECT positions) in only one, twoor three poditions of the CURRENT RANGE swit-ch (while VOLTS/AMPS switch is held in AMPSposition), the fault will be associated with the per-tinent series (current limiting) resister on resistor

TM 11-6130-356-34

plate assembly A3.(3) If such abnormal meter indications are ob-

served on CURRENT RANGE swich positions 1, 2,4, and 8, A2R42 and CURRENT ADJUST controlR2 should be checked.

(4) An abnormal meter indication observed onlyin position 10 of CURRENT RANGE switch (inboth positions of VOLT SELECT) eliminatesA2R42 and CURRENT ADJUST control R2 fromfault consideratiom

(6) If OUTPUT meter voltage indications ap-pear normal, except that abnormal variations areobserved with line or load changes, attention isdirected to the regulator circuit, primarily the in-tegrated circuit module A2U2 and the transistorseries pass elements,

d. If all panel meter indications (or responses) arenormal, but the PP-6148/U does not operate an ex-ternal load, probable fault locations(s) are eitherCB2 (the DC ON/OFF circuit breaker), or K1 andassociated components/connections which couldcause the dc output negative line to fail to close.

Item ofcheck

Relay K1

Power reactor L1

Power reactor L2

Coil L3

Transformer T1

Rectifier bridge CR1

Table 3-2. PP-6148/U Troubleshooting Chart

Testconditions

Disconnect PP-6148/U from power sourceand load.AC: OFFDC: OFFSame as above.

Same as above.

Same as above.

Same as above.

PP-6148/U connecedto power source andload.AC: ONDC: ON

MeterConnection

Use Multimeter AN/USM-223/U, RX1OO scale, to meas-ure resistance between ter-minals Xl and X2.

Use Multimeter AN/USM-229/U, RX1 scale, to meas-ure resistance between ter-minals and 2.

Same as above.

Use Multimeter AN/USM-228/U, RX1 scale, to meas-ure resistance between ter-mina1s 1 and 2.Use Multimatar AN/USM-223/U, RX1000 scale, tomeasure resistance betweenterminal 1 and 2; and RX108cale, to measure resistancebetween terminals 3 and 4.Use Multimeter AN/USM-223/U, to measure voltageacross + and - terminals,and to verify ac input at ap-propriate terminals , i fnecessary.

Normalreadings

300 ohms.

0.31 ohm.

0.0175 ohm.

B ohms.

6500/ ohms betweenterminals 1 and 2; 8.6ohms between ter-minals 3 and 4.

140 to 360 V dc acrods+ and - terminals,with ac input at ap-propriate terminals.

Additionalchecks and

remarks

Replace relay K1 if shor-ted or open:

Replace power reactor L1if open.

Replace power rdactor L2if open.Replace coil L9 if open.

Replace transformer T1 ifshort or open betweeneither or both pairs of ter-minals.

If 140 to 360 V dc across+ and - terminals is ab-sent, verify ac input atappropriate terminals;replace rectifier bridgeCR1 if ac input is normaland no dc output.

3-11

TM 11-6130-356-34

Table 3-2. PP-6148/U Troubleshooting Chart-Continued

Item ofcheck

Transistors Q1 and Q2

Transistor Q3

Item ofcheck

Relay A1K1

Relay A1K2

Relay A1K3

Transformer A1T1

Testconditions

a

b.

a

b.

Disconnect PP-6148/U from powersource and load.AC: OFFDC: OFFPP-6148/U con-nected to powersource and load.AC: ONDC: ONDisconnect PP-6148/U from powersource and load.AC: OFFDC: OFF

PP-6148/U con-nected to powersource and load.

Meterconnections

a

b.

a

b.

Use Semi-conductor De-vice Test Set TS-1836( )/U to check tran-sistors Q1 and Q2.

See figure 3-2 (A) and (B)

None.

See figures 3-1 and 3-2(c).

AC: ONDC: ON

Normalreadings

a See figure 3-1.

b. See figure 3-2(A) and (B).

a None

b. See figures 3-1and 3-2 (C).

Table 3-3. Cover Assembly Al Troubleshooting Chart

Testconditions


Same as above.

Same as above.

Meterconnections

Use Multimeter AN/USM-223/U, RX1000 scale, tomeasure resistance betweenterminals Xl and X2.

Use Multimeter AN/USM-223/U, RX100 scale, to meas-ure resistance between ter-minals Xl and X2.Use Multimeter AN/USM-223/U, RX1000 scale, tomeasure resistance betweenterminals Xl and X2.Use Multimeter, AN/USM-223/U, RX1 scale, to meas-ure resistances betweenfollowing terminals1 and 23 and 45 and 67 and 89 and 10

Normalreadings

7500 ohms.

300 ohms,

7500 ohms.

1 and 2:0.175 ohm3 and 4:0.066 ohm5 and 6:0.055 ohm7 and 8:0.055 ohm9 and 10:0.055 ohm.


remarks

a

b.

a

b.

Replace transistorsQ1 and Q2 if abnormalreadings are obtained.

Replace transistorsQ1 and Q2 if abnormalwaveforms are ob-served.

Remove transistor Q3and connect PP-6148/U to power source andload. With AC and DCO N - O F F c i r c u i tbreaker ON, deter-mine if unit operates.If it does, replace tran-sistor Q3. If it doesnot, see table 3-5 andcheck integrated cir-cuit A2U2.Replace Q3 if ab-normal vol tagesand/or waveforms areobserved.


remarks

Replace relay AlK1 ifshort or open.

Replace relay A1K2 ifshort or open.

Replace relay A1K3 ifshort or open.

Replace transformerAIT1 if open between oneor more pairs of ter-minals.

3-12

TM 11-6130--356-34

Table 3-3. Cover Assembly Al Troubleshooting Chart-Continued

Item of Teatcheck conditions

Transformer A1T2 Same as above.

Item ofcheck

Meter Normalconnections readings

Use Multimeter AN/USM- 1 and 2: 0.170 ohm223/U, RX1 scale, to meas- 3 and 4: 0.185 ohmure resistances between 5 and 7: 0.080 ohmfollowing terminals: 8 and 10: 0.019 ohm.1 and 23 and 45 and 78 and 10

Additionalchecks andremarks

Replace transformerA1T2 if open between on aor more pairs of ter-minals.

Table 3-4. Converter Circuit Card Assembly AlAl Troubleshooting ChartNOTE

When replacement of component(s) on converter circuit card assembly A1A1 is indicated in Ad-ditional check and remark column, refer to higher maintenance echelon.

Diodes A1A1CR4through A1A1CR15

Transistors A1A1Q1through A1A1Q4

Testconditions

Disconnect PP-6148/U from power sourceand load.AC: OFFDC: OFF

Same as above.

Meterconnections

Remove one end of each di-ode, and use Semi-conductorD e v i c e T e s t S e t T S -1836( )/U, to compare for-ward-to-back resistance.

Remove each transistor, anduse Semi-conductor DeviceT e s t S e t T S - 1 8 3 6 ( ) / ,RX1000 scale, to measurefor high collector-to-emitterresistance.

Normalreadings

Ratio of forward-to-back resistance shouldbe greater than 1 to100.

Collector-to-emitterresistance should begreater than 100 oh-ms.


remarksReplace if ratio of for-ward-to-back resistancefor any diode is notgreatar than 1 to 100.

NOTECheck all of these diodes;checking only part of thisgroup of diodes is notrecommendedReplace transis tor i fcollector-to-emitter resis-tance is less than 1000 oh-ms.

Table 3-5. Control Circuit Card Assembly A2 Troubleshooting ChartNOTE

When replacement of component(s) on control circuit card assembly A2 is indicated in Additionalchecks and remarks column, refer to higher maintenance echelon.

Item ofcheck

Relay A2K1

Relay A2K2 Replace relay A2K2 ifshorter or open.

Coil A2L1

Coil A2L2

Coil A2L3

TestConditions


Same as above.

Same as above.

Same as above.

Meterconnections

Use Multimeter AN/USM-223/U, RX100 scale to meas-ure resistance between ter-minals Xl and X2.

Use Multimeter AN/USM-229/U, RX1000 scale, tomeasure resistance betweenterminals Xl and X2.Use Multimetar AN/USM-223/U, RX10 scale, to meas-ure resistance between ter-minals 1 and 2.Same as above.

Same as above.

Normalreadings

700 ohms.

10000 ohms.

72 ohms.

Same as above.

Same as above.

AdditionalCheck and

remarksReplace relay A2K1 ifshort or open.

Replace coil A2L1 if tlhator open.

Replace coil A2L2 if shortor open.Replace coil A2L3 if shortor open.

3-13

TM 11-6130-356-34

Table 3-5. Control Circuit Card Assembly A2 Troubleshooting Chart-Continued

Item ofcheck

Transistor A2Q3

Integrated CircuitA2U1

Integrated CircuitA2U2

Item ofcheck

Meterconnections

Resistors A3R1through A3R6

Testconditions

PP-6148/U connectedto power source andload; power source setfor 400 Hz input.AC: ONDC: ONPP-6148/U connectedto powersource and loadAC: ONDC: ONCURRENT RANGE: 1a. PP-6148/U con-

nected to powersource and load.AC: ONDC: ON

b. Disconnect PP-6148/U frompowor sourceandload,AC: OFFDC: OFF

Meterconnections

Use Multimetar AN/USM-223/U, to measure voltagefrom terminal A2-36 to ter-minal A2-2.

Connect a 10 amp load tooutput terminals and useoutput meter to checkcurrent.

a. Use Multimeter AN/USM-29/U, to measurevoltage across A2Q5.

b. None

Normalreadings

Less than l V dc.

Not greater than 2amps.

a. Greater than 0.8V dc.

b. None.

Table 3-6 Resistor Plate Assembly A3 Troubleshooting Chart

Testconditions

Disconnect PP-6148/U from power sourceand load.AC: OFFDC: OFF

Section IV.

3-9. General

Use appropriate scale ofMultimeter AN/USM-229/U to measure resistance ofresistors A3R1 throughA3R6.

Normalreadings

A3R1: 2.2 ohmsA3R2: 1 ohmA3R3: 0.45 ohmA3R4: 0.2 ohmA3R5: 0.05 ohmA3R6: 0.2 ohm.


remarks

Replace transistor A2Q8if voltage from terminalA2-36 to terminal A2-2is greater than 1 V dc.

Replace A2U1 if currentis greatar than 2 amps.

a Replace integrated cir-cuit A2U2 if voltageacross A2Q5 is lessthan 0.8 V dc.

b. Remove transistor Q3and C o n n e c t P P -6148/U to power sourceand load. With AC andDC ON-OFF circuitbreakers ON, deter-mine if unit operates. Ifit does not replace trans-sister Q3 and in-tegrated circuit A2U2.


remarksReplace any open resis-tor.

NOTEFor resistance measurements of A3R5 andA3R6, one end of resistorA3R5 or A3R6 must bedisconnected.

MAINTENANCE OF PP-6148/U

levels should not be undertaken unless it has been

This section consists of adjustment/alinementprocedures, general parts replacement techniques,removal and replacement instructions, anddisassembly and reassembly instructions applicableto the direct support maintenance level.

3-10. Adjustment/Alinement

This paragraph details the procedure for correctlyand accurately readjusting the voltage throw-off(CHARGE OVER) levels. Readjustment of these

demonstrated that the power supply output voltageis not within the specified range (i.e.) 16.0 to 16.4 Vdc with VOLT SELECT 14V/28V switch at 14V or32.0 to 32.8 V dc with VOLT SELECT 14V/28Vswitch at 28V. Refer to TM 11-6130-356-12,paragraph 3-4, Operational Checks. out-of-range voltage throw-off (CHARGE OVER) levelshould be verified by measurement using an elec-tronic voltmeter with 0.2 percent accuracy or better,such as the ME-202( )/U, before the following ad-

3-14

justments are made. Similarly, the output voltagethrow-off (CHARGE OVER) level must bemonitored, with the ME-202( )/U at 0.1 V dc fullscale sensitivity as the final adjustment are made.

a. Be sure that the maximum dc output voltagelevel of the PP-6148/U reasonably exceeds thevoltage throw-off (CHARGE OVER) level to be set

(1) If the levels indicated on the front panelOUTPUT meter are not greater than 16.4 V dc withthe VOLT SELECT 14V/28V switch at 14V, andgreater than 32.8 V dc with the VOLT SELECT14V128V switch at 28V, unlock and operate theVOLTAGE ADJUST control to verify that theseoutput levels can be obtained (If necessary, operateand hold the CHARGE RESET switch to preventtrip-out while making these checks. Be sure theswitch returns to the normal (up) position.)

(2) With the VOLT SELECT 14V/28V switchat 14V, operate the VOLTAGE ADJUST controlfor a front panel OUTPUT meter indication of 16 Vdc, or just below trip-out level, whichever is lower.

b. Set the AC and DC ON/OFF circuit breakers toOFF, remove cover assembly Al and connect theME-202( )/U to suitably monitor the dc outputlevel. Use an internal negative connection tofacilitate voltmeter nulling at the tripout level.

c. Set the AC and DC ON/OFF circuit breakers toON, and operate the VOLTAGE ADJUST controlto obtain an exact 16.9 V dc level as indicated on theME-202( )/U (nuol function).

NOTEIf necessary, operate and hold theCHARGE RESET switch to preventvoltage throw-off circuit trip-out.

d. With the output level precisely set, observe theCHARGE OVER indicator, and adjust poten-tiometer A2R33 (fig. 4-2) carefully for trip-outthreshold at this set level.

NOTEIf the trip-out level was low, poten-tiometer A2R33 should be adjusted in theclockwise direction if high, poten-tiometer A2R33 should be adjusted in thecounterclockwise direction.

e. Opera te CHARGE RESET swi tch andVOLTAGE ADJUST control alternately to verifythat trip-out does not occur below 16.2 V dc, norhold above 16.4 V dc as finally adjusted.

f. Repeat subparagraph c and d above withVOLT SELECT 14V/28V switch at 28V, with theoutput level set at 32.6 V dc, and adjusting poten-tiometer A2R26 (fig. 4-2) to obtain the desire tripout level for this range.

g. Repeat subparagraph e above to verify that

TM 11-6130-356-34

trip-out does not occur below 32.4 V dc, nor holdabove 32.8 V dc as finally adjuted

h. Set the AC and DC ON/OFF circuit breakers toOFF, disconnect the ME-202( )/U and reassembleand secure cover assembly Al.

i. Reconnect the ME-202( )/U to suitablymonitor the dc output level, again operate thePP-6148/U, and make a final check to verify thatthe voltage throw-off levels remain within 16.1 to16.4 V dc on the 14V range, and 32.2 to 32.8 V dc onthe 28V range before the PP-6148/U is returned toservice.

3-11. General Parts Replacement Techniques

All subassemblies and components of thePP-6148/U can be replaced without specialprocedures. The following precautions apply, hewer,specifically to this equipment.

a. Do not disturb the setting of any poten-tiometer.

b. The PP-6148/U is transistorized. Use a pencil-type soldering iron with a 25-watt maximumcapacity. If the iron must be used with ac voltage,use on isolating transformer between the iron andthe line. Use a higher-wattage soldering iron forheavier-duty soldering.

CAUTIONDo not use a soldering gun; damagingvoltage may be induced into components.

c. When soldering semiconductor leads, solderquickly. Whenever wiring permits, use a heat sink(such as long-nosed pliers) between the solderedjoint and the semiconductor. Use approximately thesame length and dress of leads as used originally.

3-12. Repair

Locate the defective component or part with the aidof the parts location illustration: figure 3-3 for coverassembly Al, figure 3-4 for resistor plate assemblyA3, and figure 3-5 for chassis mounted components.

3-13. Disassembly Instructions

Disassembly of the PP-6148/U is to be ac-complished to the extent necessary to correctmalfunctions. The instructions have been separatedby areas. Disassemble the PP-6148/U in accordancewith the applicable area to be repaired. Disconnectthe power source, and set the AC and DC ON/OFFswitches to OFF before beginning disassembly.Comply with precautionary instructions to avoid in-jury to personnel and damage to equipment. Beforedisconnecting a component, tag and identify all itsconnecting leads, connecting terminals or con-necting points to facilitate reconnection.

3-15

TM 11-6130-356-34

Figure 3-3. Cover Assembly A1, Parts Location Diagram.

3-16 Change 1

TM 11-6130-356-34

3-14. Removal, Disassembly and Reassembly ofCover Assembly Al

(fig. 3-3)

Legend for figure 3-3:1.2.3.4.5.6.7.8.9.

10.11.12.13.14.

Converter cicuit card assembly AlAlScrews (6) and washers (12)Relay A1K1Relay A1K2Relay A1K3Screws (2), washers (4), and spacers (2)Semiconductor device A1CR1Transformer A1T1Nut and washers (2)Transformer A1T2Nuts (4) and washers (8)Resistor AlR1Nuts (2) and washers (4)Transistors A1Q1 through A1Q4

15. Screws (2), washers (2), and disk

a. Removal. Remove cover assembly A1 (3, fig.3-5) by loosening 14 captive screws (4).

b. Disassembly.(1) Disconnect leads and remove converter cir-

cuit card assembly Al Al (1, fig. 3-3) by removingsix screws and 12 washers (2).

NOTEComponents of converter circuit cardassembly AlA1 are to be removed andreplaced at the general support level only.

(2) Remove relay A1K1 (3), A1K2 (4) and A1K3 (5) by disconnecting leads and removing two screws,

four washers, and two spacers (6) in each case.(3) Remove semiconductor device A1CR1 (7)

and transformer A1T1 (8) by disconnecting theleads and removing one nut and two washers (9) ineach case.

(4) Remove transformer A1T2 (10) by discon-necting its leads, and removing four nuts and eightwashers (11).

(5) Remove resistor AlR1 (12) by disconnectingits leads, and removing two nuts and four washers(13).

(6) Remove transistors A1Q1 through A1Q4(14) by disconnecting the leads, and removing twoscrews, two washers and one disk (15) in each case.

c. Reassembly.(1) Reinstall card assembly A1A1 (1) with six

screws and twelve washers (2). Reconnect leads.(2) Remount relays A1K1 (3), A1K2 (4), and

A1K3 (5) by coating threads of spacers with sealingcompound MIL-S-22473 (item 1, appx B), thenreinstalling with two screws, four washers and twospacers (6) in each case. Reconnect leads.

(3) Remount semiconductor device A1CR1 (7)and transformer AlT1 (8) with one nut and twowashers (9) in each case. Reconnect leads.

(4) Remount transformer A1T2 (10) with fournuts and eight washers (11). Reconnect leads.

(5) Remount resistor A1R1 (12) with two nutsand four washers (13). Reconnect leads.

(6) Remount transistors A1Q1 through A1Q4(14) by applying a thin layer of grease DC340-50Z(item 2, appx B) to both sides of disk, and then rein-stalling with two screws, two washers, and one disk(15) in each case. Reconnect leads.

3-15. Removal, Disassembly and Reassembly ofControl Circuit Card Assembly AZ

a. Removal. Remove cover assembly Al (3, fig.3-5) by loosening 14 captive screws (4).

b. Disassembly. Disconnect all leads from controlcircuit card assembly A2 (6, fig. 3-5). Remove con-trol circuit card assembly A2 by removing twoscrews and mounting clips (7), and four screws andeight washers (8).

N O T EComponents of control circuit cardassembly A2 are to be removed andreplaced at the general support level only.

c. Reassembly. Replace control circuit cardassembly A2 (6) in the PP-6148/U with two screwsand mounting clips (7), and four screws and eightwashers (8). Reconnect leads. Apply sealing com-pound MIL-S-22473 (item 1, appx B) to the twoscrews and mounting clips (7) after replacement.

3-16. Removal, Disassembly and Reassembly ofResistor Plate Assembly A3

(fig. 3-4).

Change 1 3-17

TM 11-6130-356-34

1.2.3.4.

Resistor A3R4 5. Resistor A3R3Nuts (2) and washers (4) 6. Resistor A3R5Resistor A3R1 7. Resistor A3R6Resistor A3R2 8. Nuts (2) and washers (2)

Figure 3-4. Resistor Plate Assembly A3, Parts Location Diagram

a. Removal. Remove cover assembly Al (3, fig.3-5) by loosening 14 captive screws (4).

b. Disassembly.(1) Disconnect all leads from resistor plate

assembly A3 (9, fig. 3-5). Remove resistor plateassembly A3 by removing four nuts and eightwashers (10).

(2) Disconnect leads from resistor A3R4 (1, fig.3-4). Remove A3R4 by removing two nuts and fourwashers (2).

(3) Disconnect leads from resistors A3R1 (3),A3R2 (4), A3R3 (5), A3R5 (6), and A3R6 (7). Removeresistors by removing two nuts and two washers (8)in each case.

c. Reassembly.(1) Reinstall resistor A3R4 (1) with two nuts

and four washers (2). Reconnect leads.(2) Replace resistors A3R1 (3), A3R2 (4), A3R3

(5), A3R5 (6), and A3R6 (7) with two nuts and twowashers (8) in each case. Reconnect leads.

(3) Replace resistor plate assembly A3 (9, fig.3-5) in the PP-6148/U with four nuts and eightwashers (10). Reconnect leads.

3-17.

3-18

Disassembly and Reassembly of ChassisMounted Components

(fig. 3-5)

Legend for figure 3-5(1):1.2.3.4.5.6.

7.

8.9.

10.11.12.13.14.15.16.17.18.19.20.21.22.23.24.

25.26.27.

Cover assemblyGasketCover assembly AlCaptive screws (14)Electronic shielding gasketControl circuit card

assembly A2Screws (2) and mounting

clips (2)Screws (4) and washers (8)Resistor plate assembly A3Nuts (4) and washers (8)Filters FL1 and FL2Filters FL3 and FL4Capacitors C1 through C4Capacitor C5Capacitors C6 and C7Capacitor CRKnobSwitch S1Switch S2Switches S3 and S4BootResistor R1Resistor R2CHARGE OVER indicator

DS1, housing and lensOUTPUT meter MlWashers (4)DC output connector J2

28.

29.30.31.32.33.

34.35.36.37.

38.39.

40.41.42.43.44.45.46.47.48.49.50.51.

Screws (4), washers (10),plate, and flat washer

Power reactor L1Power reactor L2Nuts (4) and washers (8)Relay K1Screws (2), washers (4),

and spacers (2)Rectifier bridge CR1Nut and washers (2)Diode CR2Nut, flat washer, lock-

washer, insulatingwashers (2), terminal lug,and bushing

Transistors Q1 and Q2Screws (2), washers (2),

and insulatorTransistor Q3Heat sinkScrewTransformer T1Nuts (2) and washers (4)Diode plate assemblyScrews (2) and washers (4)Circuit breaker CB1Circuit breaker CB2PlateScrews (5) and washers (10)AC INPUT connector J1

TM 11-6130--356-34

Figure 3-5(1). PP-6148/U Chassis Mounted Components,Parts Location Diagram (Sheet 1 of 2). Change 1 3-19

Figure 3-5(2).

TM 11-6130-356-34

3-20 Change 1

TM 11-6130-356-34

a. Cover Assembly. Unclamp and remove coverassembly (1). Remove gasket (2), if necessary.

b. Cover Assembly A1. Remove cover assemblyA1 (3) by loosening 14 captive screws (4), andremove electronic shielding gasket (5) if necessary.

WARNINGDischarge capacitors before continuingwith following procedures.

c. Filters FL1 and FL2 (11), FL3 and FL4 (12).Disassembly and reassembly of these filters is ac-complished employing standard shop techniques.Apply sealing compound RTV-732 (item 3, appx B)to FL3 and FL4 (12) after replacement.

d. Capacitors C1 through C4 (13), C5 (14), C6 andC7 (15), and C8 (26). Disassembly and reassembly ofthese capacitors is accomplished employing stan-dard shop techniques. Apply sealing compoundRTV-732 (item 3, appx B) to C8 (16) afterreplacement,

e. Switches S1 (18), S2 (19), S3 and S4 (20).(1) Disassembly. Remove knob (17) from S2 (19)

by loosening its setscrew. Disconnect leads fromswitch. S1 through S4 are removed by loosening andremoving attaching hardware. Remove boot (21 )from S1 (18), and S3 and S4 (20).

(2) Reassembly. Reinstall knob (17) on switchS2 (19), and reinstall S1 through S4 with hardwarepreviously removed. Replace boot (21) on S1 (18),and S3 and S4 (20). Reconnect leads.

f. Resistors R1 (22) and R2 (23).(1) Disassembly. Disconnect leads and remove

attaching hardware.(2) Reassembly. Remount resistors with hard-

ware previously removed. Reconnect leads.g. CHARGE OVER Indicator DSl (24).

(1) Disassembly. Unscrew counterclockwise un-til threads are disengaged, If necessary, separatethe indicator from the lens.

(2) Reassembly. Replace housing with indicatorand lens (24), with rubber O-ring in place. Re-engage threads and tighten fingertight, making surethat the rubber O-ring seats and seals properly.

h. OUTPUT Meter Ml (25).(1) Disassembly. Remove leads. Remove meter

(25) by loosening and removing attaching hardwareand four washers (26).

(2) Reassembly. Remount meter (25) with at-taching hardware and four washers (26). Reconnectleads.

i. De Output Connector J2 (27).(1) Disassembly. Disconnect leads. Remove

connector (27) by removing four screws, tenwashers, one plate and one flat washer (28).

(2) Reassembly. Reinstall connector (27) with

four screws, ten washers, one plate, and one flatwasher (28).

j. Power Reactors L1 (29) and L2 (30).(1) Disassembly. Disconnect leads from

reactors (29) and (30). Remove reactors by removingfour nuts and eight washers (31 ).

(2) Reassembly. Reinstall reactors (29) and (30)with four nuts and eight washers (31). Reconnectleads.

k. Relay Kl (32). Disconnect leads, Remove K1(32) by removing two screws, four washers, and twospacers (33). Reinstall relay (32) with two screws,four washers, and two spacers (33). Reconnect leads.Apply sealing compound MII.-S-22473 (item 1,appx B) to the relay.

1. Rectifier Bridge CR1 (34). Disconnect leads.Remove CR1 (34) by removing one nut and twowashers (35). Reinstall CR1 (34) with one nut andtwo washers (35). Reconnect leads.

m. Diode CR2 (36). Disconnect leads. RemoveCR2 (36) by removing one nut, one flat washer, onelockwasher, two insulating washers, one terminallug, and one bushing (37). Reinstall CR2 (36) withone nut, one flat washer, two insulating washers,one terminal lug, and one bushing (37). Reconnectleads.

n. Transistor Q1 and Q2 (38).(1) Disassembly. Disconnect leads. Remove

transistors by removing two screws, two washers,and one insulator (39).

(2) Reassembly. Apply a thin layer of greaseDC 340-502 (item 2, appx B) to insulator, andreinstall transistor (38) with two screws, twowashers, and insulator (39), Reconnect leads.

o. Transistor Q3 (40).(1) Disassembly. Disconnect leads. Remove

transistor (40) and its heat sink (41) by removing onescrew (42).

(2) Reassembly. Apply a thin layer of greaseDC 340-502 (item 2, appx B) to heat sink (41).Reinstall transistor (40) and heat sink (41) withscrew (42). Reconnect leads.

p. Transformer TI (43). Disconnect leads. RemoveT1 (43) by removing two nuts and four washers (44).Reinstall T1 (43) with two nuts and four washers(44). Reconnect leads,

q. Diode Plate Assembly (45) Disconnect leads.Remove diode plate assembly (45) by removing twoscrews and four washers (46). Remount diode plateassembly (45) with two screws and four washers(46). Reconnect leads.

r. Circuit Breakers CB1 (47) and CB2 (48).Disconnect leads. On serial numbers 155A and up,disconnect leads and resistors R8 through R11 fromCB1. Remove circuit breaker by removing its

Change 1 3-21

TM 11-6130-356-34

attaching hardware. Reinstall circuit breaker withattaching hardware. Reconnect leads. On serialnumbers 155A and up, reconnect leads and resistorsR8 thru R11 to CB1. Apply insulating compoundRTV-3 140( item 4, appx B) after replacement.

s. AC INPUT Connector Jl (51).(1) Disassembly. Remove plate (49) by

removing five screws and 10 washers (50). Dis-connect leads to connector J1. Remove connectorJ1 (51) by loosening and removing its attachinghardware.

(2) Reassembly. Reinstall connector J1 (51)with its attaching hardware. Reconnect leads.

Replace plate (49) with five screws and 10 washers(50).

t. If previously removed, replace gasket (5) bycutting gasket 07-0101-004 (item 5, appx B) torequired length and affixing with adhesive 1711SCOTCH -GRIP (item 6, appx B). Replace coverassembly A1 (3) by tightening 14 captive screws (4).

u. If previously removed, replace gasket (2) bycutting gasket R431N (item 7, appx B) to requiredleng th and a f f ix ing wi th adhes ive 1711SCOTCH-GRIP (item 6, appx B). Clamp coverassembly (1) to PP-6148/U.

Section V. DIRECT SUPPORT TESTING PROCEDURES

3-18. General 3-19. Modification Work Orders

Direct support testing procedures are required to Currently, MWO 11-6130-50-1 is applicable to thedetermine whether the performance of repaired PP-6148/U .equipment is satisfactory for its return to users.Each of the following test procedure charts is 3-20. Physical Test and Inspection

preceded by appropriate instructions for setting up a. Test Equipment and Materials. Tool Kit,and interconnecting any applicable test equipment Electronic Equipment TK-105/G.to the equipment to be tested. Be sure to follow the b. Procedure.procedural steps in the order given and set allcontrols accurately.

StepN o .

1

2

3

4

5

6

Control settings

Test EquipmentTool Kit, Electronic EquipmentTK-105/G

N/A

N/A

N/A

Tool Kit, Electronic EquipmentTK-105/G

N/A

Equipment undert e s t

Controls may be in anyposition.






Test procedureInspect all controls andswitches for loose ormissing hardware.

Inspect ac power input cablefor any e v i d e n c e o fcorrosion, loose connections,or damaged insulation.Inspect battery chargeradapter cable for any eviden-ce of corrosion, loose con-nections, or damaged in-sulation,Inspect handle for anyevidence of cuts, tears, orweakening when the protec-tive top panel cover issecured to the PP-6148/UInspect external terminalsfor loose hardware or anyevidence of dirt or corrosion.Inspect exterior metal sur-faces of the PP-6148/U forexcessive dust, dirt, grease,or moisture and any evidence of rust or corrosion.

Performancestandard

Hardware must bet i g h t ; nonemissing.

No corrosion, loosec o n n e c t i o n s , o rdamaged insulation.

No corrosion, looseconnections, ordamaged insulation.

No cuts, tears, orweakening.

Hardware must betight; no dirt orcorrossion evident.No dust, dirt, greasemoisture, r u s t , o rcorrosion.

3-22 Change 1

TM 11-6130-356-34

3-21. Voltage Tests, Input and Output b. Test Connections and Conditions. The test

a Test Equipment and Materials.(1) Transformer, Variable Power TF-510/U.(2) Ac power input cable.(9) Multimeter AN/USM-223/U (2 required).(4) Voltmeter, Electronic ME-202( )/U.(5) Dummy Load, Electrical DA-638/U.(6) 115-230 volt, 400 Hz power source.

procedures for performing the voltage tests are to beperformed with the PP-6148/U disconnected fromits operational load (communications equipment orbattery to be charged). Figure 3-6 shows the basicteat setup to be used for performing the voltagetests, as well as other tests in this section

Figure 3-6. Basic Tent Setup Diagram

c . In i t ia l Tes t Equipment Se t t ings . C o n n e c t t h e minute warmup period before starting the procedure

test equipment to the power source and allow a 10- in paragraph d below.

d. Procedure.

StepNo.

1

2

Control Settings

Test Equipment

TF-510/U, AN/UsM-229/U,and ME-202( )/U: POWER:OFFTF-510/U: Set for 116 Vac/60Hz operation as read onAN/USM-229/U. (Readjustduring test as necessary.)DA-638/U: Set for an AmmeterAN/USM-223/U reading of 0amps. (Disconnect load ifnecessary.)

Equipment under test

AC: OFFDC: OFF

VOLT SELECT 14V/28V: 14VCURRENT RANGE: 10VOLTAGE ADJUST:Set fully counterclockwieeAC: ONDC: ON

Teat procedure

Connect the test equipmentto the power supply asshown in figure 3-6.a. Set AC ON-OFF and DC

ON-OFF switches to ONposition.

b. Slowly rotate VOLTAGEA D J U S T c o n t r o lclockwise.

Performance standard

None

a. ME-202( )/U indi-cates no more than12.0 V dc.

b. CHARGE OVERindica tor l ightswhen o u t p u tvoltage is between16.0 and 16.4 V dc( a s r e a d o nME-202( )/U.

3-23

TM 11-6130-356-34

d. P r o c e d u r e - C o n t i n u e d .

Control Settings

StepNo. Test Equipment

c.(cont)

d.

e .

g .

h.

i .

3 Same as step No. 2.

Equipment under test Tes t procedure

Same as step No. 2, exceptVOLT SELECT 14 V/28V:28V.

j.

a.

b.

c.

d.

Reduce output voltagebelow 16.0V dc and pressC H A R G E R E S E Tswitch to down position.R o t a t e V O L T A G EADJUST control fullyclockwise, while holdingC H A R G E R R E S E Tswitch down.Set the DA-638/U for anAN/USM-223/U readingof 5.0 ± 0.2 amps andr o t a t e V O L T A G EA D J U S T c o n t r o lcounterclockwise untilME- 202( )/U indicates16.0 ± 0.1 V dc.Set the DA-638/U for anAN-USM-223/U readingof 8.5 ± 0.5, 0.0 amps.Set the DA-638/U for anAN/USM-223/U readingof 0 amps. (Disconnectload if necessary.)Set the DA-638/U for anAN/USM-223/U readingof 5.0 ± 0.2 amps andr o t a t e V O L T A G EA D J U S T c o n t r o lcounterclockwise untilME- 202( )/U indicates12.0 ± .01 V dc.Set the DA-638/U for anAN/USM-223/U readingof 8.5 + 0.5, 0.0 ampsSet the DA-638/U for anAN/USM-223/U readingof 0 amps. (Disconnectload if necessary.]Verify AC ON-OFF andDC ON-OFF switches inON position.Slowly rotate VOLTAGEA D J U S T c o n t r o lclockwise.

Reduce output voltagebelow 32.0 V dc and pressC H A R G E R E S E Tswitch to down position.While holding CHARGERESET switch down,r o t a t e V O L T A G EADJUST CONTROLc l o c k w i s e u n t i lME-202( )/indicates atleast 33.0 V dc.


c. CHARGE OVERindicator goes out.

d. ME-202( )/U indi-cates at least 16.5V dc.

e. ME-202( )/U indi-cates 16.0 ± 0.1 Vdc.

f. ME-202( )/U indi-cates 16.0 ± 0.1 Vdc ± 2.0%

g. ME-202( )/U indi-cates 16.0 ± 0.1 Vdc ± 2.0%

h. ME-202( )/U indi-cates 12.0 ± 0.1 Vdc.

i. ME-202( )/U indi-cates 12.0 ± 0.1vdc ± 2.0

j. ME- 202( )/U indi-cates 12.0 ± .01 Vdc ± 2.0%

a. ME-202( )/U indi-cates no more than24.0 V dc.

b. CHARGE OVERindica tor l ightswhen o u t p u tvoltage is between32.0 and 32.8 V dc(as r e a d o nME-202( )/U.

c. CHARGE OVERindicator goes out.

d. ME- 202( )/U indi-cates at least 33.0V dc.

3-24 Change 1

TM 11-6130-356-34

d. P r o c e d u r e - C o n t i n u e d .

StepNo.

3(cont)

4 a.

5

Control Settings

Test Equipment

Same as step No. 2.

Same as step No. 2.


Same as step No. 2.


Test procedure

Set the DA-638/U for anAN/USM-223/U readingof 5.0 ± 0.2 amps andr o t a t e V O L T A G EA D J U S T c o n t r o lcounterclockwise untilME-202( ) U indicates24.0 ± 0.1 V dc.Set the DA-638/U for anAN/USM-223/U readingof 8.5 + 0.5, -0.0 amps.Set the DA-638/U for anAN/USM-223/U readingof 0 amps (Disconnectload if necessary.)Set the DA-638/U for anAN/USM-223/U readingof 5.0 ± 0.2 amps androtate VOLTAGE AD-JUST control clockwiseuntil ME-202( )/U in-dicates 32.0 ± 0.1 V dc.Set the DA-638/U for anAN/USM-223/U readingof 10.0 ± 0.5 amps.Set the DA-638/U for anAN/USM-223/U readingof 0 amps. (Disconnectload if necessary. )Rotate VOLTAGE AD-JUST control clockwiseuntil ME-202( )/U in-dicates 14.0 ± 0.1 V dc.

Set the DA338/U for anAN/USM-223/U readingof 8.5 + 0.5, –0.0 amps,and hold the VOLTS/AMPS switch onPP-6148/U top panel inAMPS Position.

c. Set the DA-638/U foran AN/USM-223/Ureading of 0 amps(Disconnect load ifnecessary.)

a. Rotate VOLTAGEADJUST control clock-wise until ME-202( )/Uindicates 28,0 ± 0.1 Vdc.

b. Set the DA-638/U for anAN/USM–223/U readingof 8.5 + 0.5, –0.0 amps,and hold the VOLTS/AMPS switch.


e ME - 202( )\U indi-cates 24.0 ± 0.1 Vdc.

f. ME-202( )/U indi-cates 24.0 ± 0.1 Vdc ± 1.5%

g. ME-202( )/U indi-cates 24.0 ± 0.1 Vdc ± 1.5%

h. ME-202( )/U in-dicates 32.0 ± 0.1V dc.

i. ME-202( )/U in-dicates 32.0 ± 0.1V dc ± 1.5%.

j. ME-202( )/U in-dicates 32.0 ± 0.1V dc ± 1.5%.

OUTPUT meter onPP-6148/U toppanel indicates14.0 ± 0.1 V dc ±approximately one-half a meter facedivision.

b. OUTPUT meter onPP-6148/U toppanel indicates10.0 ± 0.5 amps ±approximately one-half a meter facedivision.

c. ME-202( )/U indi-cates 14.0 ± 0.1 Vdc± 2.0%.

a. OUTPUT meter onPP-6148/U toppanel indicates 28.0±0.1 V dc ± ap-proximately one-half a meter facedivision.

b. OUTPUT meter onPP-6148/U toppanel indicates 10.0±0.5 amps ± ap-proximately one-

Change 1 3-25

TM 11-6130-356-34

d . P r o c e d u r e – C o n t i n u e d .

StepNo.5

(cont)

6

7

8

Control Settings

Test Equipment

Same as step No. 2

Same as step No. 2.

TF-510/U: Set for 230 Vac/60Hz operation as read onAN/USM-223/U. (Readjustduring test as necessary.)D A - 6 3 8 / U : S e t f o r a nAN/USM-223/U reading of 0amps. (Disconnect load ifnecessary.)


c.

VOLT SELECT 14V/28V: 14V a.CURRENT RANGE: 10VOLTAGE ADJUST: Setfully counterclockwiseAC: ON b.DC: ON

c .


Same as step No. 6.

Tes procedure

on PP-6148/U topp a n e l i n A M P Sposition.Set the DA-638/U foran AN/USM-223/Ureading of 0 amps.(Disconnect load ifnecessary.)Set the DA-638/U foran AN/USM-223/Ureading of 5.0 ± 0.2 am-ps.Rotate VOLTAGEADJUST control clock-wise until ME-202( )/Uindicates 14.0 ± 0.l Vdc.Set the DA 638/U foran AN/USM-223/Ureading of 8.5 ± 0.5, 0.0amps.

d. Set the DA-638/U foran AN/USM-223/Ureading of 0 amps.(Disconnect load ifnecessary).

a. Set the DA-638/U for

b

c.

d

a

b.

c.

d.

an AN-USM-223/Ureading of 5.0 ± 0.2 am-ps.Rotate VOLTAGEADJUST control clock-wise until ME-202( )/Uindicates 28.0 ± 0.1 Vdc.Set the DA638/U forall AN/USM-223/Ureading of 8.5± 0.5, 0.0ampsSet the DA-638/U foran AN/USM-223/Ureading of 0 amps.(Disconnect load ifnecessary.)Set the DA-638/U foran AN/USM-223/Ureading of 5.0 ± 0.2 am-ps.Rotate VOLTAGEADJUST control clock-wise until ME-202( )/Uindicates 14.0 to 0.1 Vdc.Set the DA-638/U foran AN/USM-223/Ureading of 8.5 + 0. 5, 0.0amps.Set the DA-638/U foran AN/USM-223/Ureading of 0 amps.(Disconnect load ifnecessary)


half a meter facedivision.

c. ME-202( )/U in.dicates 28.0 ± 0.1 Vdc ± 1.5%.

a. None.

b. ME-202( )/U in-dicates 14.0 ± 0.1 Vdc.

c. ME-202( )/U in-dicates 14.0 ± 0.1 Vdc ± 2.0%.

d. ME-202( )/U in-dicates 14.0 ± 0.1 Vdc 2.0%.

a. None.


c. ME -202( )/U in-dicates 28.00.1 V dc± 1.5%.

d. ME-202( )/U in-dicates 28.0 ± 0.1 Vdc ± 1.5%.

a. None


c. ME-202( )/U in-dicates 14.0 ± 0.1 Vdc 2.0%.

d. ME-202( )/U in-dicates 14.0 ± 0.1 Vdc 2.0%.

3-26 Change 1

d. P r o c e d u r e – C o n t i n u e d .

StepNo.

9

10

11

12

Control Settings

Test Equipment

Same as step No. 8.

TF-510/U: Set for 115 Vat/400 Hz operation as read onAN/U SM-223/U. (Readjustduring test as necessary.)DA-638/U: Set for an AN/USM-223/U reading of 0 amps.(Disconnect load if necessary.)

TF-510/U: Set for 230 Vat/400 Hz operation as read onAN/USM-223/U. (Readjustduring test as necessary.)DA-638/U: Set for anAN/USM-223/U reading of 0amps, (Disconnect load ifnecessary.)TF-510/U, AN/USM-223/U,and ME-202( )/U: POWER:OFF


Same as step No. 6, exceptVOLT SELECT 14V/28V:28V.

Same as step No. 6 and 7.


DC: OFFAC: OFF

Test procedure

a. Set the DA-638/U foran AN/USM-223/Ureading of 5.0 ± 0.2 am-ps.

b. Rotate VOLTAGEADJUST control clock-wise until ME-202( )/Uindicates 28.0 ± 0.1 Vdc.

c. Set the DA-4338/U foran AN/USM-223/Ureading of 8.5 + 0.5, –0.0amps.

d. Set the DA-638/U foran AN/USM-223/Ureading of 0 amps.(Disconnect load ifnecessary. )



Disconnect all test equipment from the PP-6148/U.

TM 11-6130-356-34


a. None.


C . ME-202( )/U in-dicates 28.0 ± 0.1 Vdc ± 1.5%.

d. ME-202( )/U in-dicates 28.0 ± 0.1 Vdc + 1.5%.

Same as step No. 6and 7.

Same as step No. 6and 7.

None

3-22. Recovery Time Test (5) Dummy Load, Electrical DA-638/U.b . T e s t C o n n e c t i o n s a n d C o n d i t i o n s . T h e t e s t

a. Test Equipment and Materials.(1) Ac power input cable.

procedures for performing the recovery time test are

(2) Mul t imeter AN/USM-223/U.to be performed with a power source input voltage

(3) Voltmeter, Electronic ME-202( )/U.of 115 Vac/60Hz. Figure 3-7 shows the test setup to

(4) Oscilloscope AN/USM-281.be used for performing the recovery time test.

Change 1 3-27

TM 11-6130-356-34

Figure 3-7. Recovery Time Test Setup Diagram.

c. Initial Test Equipment Settings. Connect the 10-minute warmup period before starting thetest equipment to the power source and allow a procedure in subparagraph d below.

d. P r o c e d u r e .

StepNo.

1

2

3

4

Control Settings

Test EquipmentAN/USM-223/U, ME-202( )/U,and AN/USM-281: POWER:OFFDA-638/U: Set for an AN/USM-223/U reading of 10.0± 0.5 amps.

Same as step No. 2.

Same as step No. 2; in addition,set AN/USM-281 time base andvertical amplitude to con-venient scales (calibrated), tomeasure 25 milliseconds and dcvoltage as required.

Equipment under testAC: OFFDC: OFF

VOLT SELECT 14V/28V:14V CURRENT RANGE: 10AC: ONDC: ON

Same as Step No. 2, exceptDC: OFF

Same as step No. 2, exceptAC: OFF

Test procedure

Connect the test equipmentto the PP-6148/U as shownin figure 3-7.Adjust VOLTAGE AD-JUST control for a readingon the ME-202 ( )/U of 14.0± 0.1 V dc.

Disconnect the AN/USM-223/U from between theequipment under test andDA-638/U, and insert atoggle switch in its place asshown in figure 3-7, makingsure that toggle switch is inthe open position.a. Observing AN/USM-

281, set AC ON-OFF cir-cuit breaker to ON.

Performance standardNone.

ME-202( )/U indi-cates 14.0 ± 0.1 Vdcand AN/USM-223/Uindicates 8.5 + 0.5,0.0 amps.

a. Output voltage re-turns to 14.0 ± 0.1 Vdc ±2% within 25milliseconds, andany transient (voltspeak-to-peak (vpp))

3-28 Change 1

TM 11-6130-356-34

d. Procedure-Continued.

StepNo.4

(cont)

5

6

7

Control settings

Test Equipment

Same as step No. 2.

Same as step No. 2, except DA-638/U: Set for maximumresistance.

Same as step No. 4.


Same as step No. 2, exceptVOLT SELECT 14V/28V:28V and AC: OFF.

Same as step No. 2, exceptDC: OFF.

Same as step No. 4

Test procedure

b. Observing AN/U SM -281, set AC ON-OFF Cir-cuit breaker to OFF.

Observing AN/USM -281, set AC ON-OFF cir-cuit breaker to ON, and settoggle switch to the closedposition.

Observing AN/USM-281,set AC ON-OFF circuitbreaker to OFF.

Set DC ON-OFF circuitbreaker to OFF and setAC ON-OFF circuitbreaker to ON; then, setDC ON-OFF circuitbreaker to ON.Set toggle switch to theopen position.

Set AC ON-OFF circuitbreaker to OFF, set VOLTSELECT 14V/2)V to 28V,hen return AC ON-OFF cir-cuit breaker to ON (leavingCURRENT RANGE switchset to 10). Adjust VOLT-AGE ADJUST control for arading on ME-202( )/U of28.0 ±0.1 V dc.With toggle switch in theopen position, connect theAN/USM-223/U across thetoggle switch as shown infigure 3-7. Set DC ON-OFFcircuit breaker to ON, andadjust the DA-638/U for anAN/USM-223/U reading of8.5 + 0.5, –0.0 amps.a. Remove the AN/USM-

223/U from the circuit.Observing AN/USM-81, set AC ON-OFFcircuit breaker to ON.

Performance standardoccuring does notexceed 20% ofabove level.

b. Any transient (vpp)occuring does notexceed 20% of 14.0±0.1 V dc ± 1%.

c. Output voltage re-turns to 14.0 ±0.1 Vdc ±1% within 26milliseconds, andany transient (vpp)occurring does notexceed 20% ofabove level.

d. Any transient (vpp)occurring does notexceed 20% of 14.0±0.l V dc ±l%.

e.. None.

f. Output voltagereturns to 14.0 ±0.1V dc ± 1% within 26milliseconds, andany transient (vpp)occurring does notexceed 20% ofabove level.

ME-202( )/U indi-cates 28.0 ±0.1 V dc.

AN/USM-223/U indi-cates 8.5 + 0.5, –0.0amps.

a. Output voltagereturns to 28.0 ±0. 1V dc ± 1% within 25milliseconds, andany transient (vpp)occurring does notexceed 20% ofabove level.

Change 1 3-29

TM 11-6130-356-34

d. P r o c e d u r e - C o n t i n u e d

StepNo.

7(cont)

8

Control Settings

Test Equipment

AN/USM-223/U, ME-202( )/U,and AN/USM-281: POWER:OFF

3-23. Ripple Voltage Testa. Test Equipment and Materials.

(1) Ac power input cable.

Equipment under test Test procedure Performance standard—

DC: OFFAC: OFF

b. Observing AN/USM-281, set AC ON-OFF cir-cuit breaker to OFF.

c. Observing AN/USM-281, set AC ON-OFFcircuit breaker to ON, andset toggle switch to theclosed position.

d. Observing AN/USM-281, set AC ON-OFFcircuit breaker to OFF.

e. Set DC ON-OFF circuitbreaker to OFF and setA C O N - O F F c i r c u i tbreaker to ON; then, setD C O N - O F F c i r c u i tbreaker to ON.

f. Set toggle switch to theopen position.

Disconnect all test equip-ment from the PP-6148/U.

b. Any transient (vpp)occurring does notexceed 20% of 28.0±0.1 V dc ±1%.

c. Output vol tagereturns to 28.0 ±0.1V dc ±1% within 25milliseconds, andany transient (vpp)occurring does notexceed 20% ofabove level.

d. Any transient (vpp)occurring does notexceed 20% of 28.0±0.l V dc ±l%.

e. None.

f. O u t p u t v o l t a g ereturns to 28.0 ±0.1V dc ± 1%. within25 milliseconds, andany transient (vpp)occurring does notexceed 20% of above level.

None.

voltage of 28.0 V dc, 10 amperes load current. Thebasic test setup shown in figure 3-6 is the test setupto be used for the ripple voltage test. The only ex-ception is that the Variable Power Transformer(2) Multimeter AN/USM-223/U.

(3) Voltmeter. Electronic ME-202( )/U. TF-510/U and Multimeter AN/USM-223/U used(4) Oscilloscope AN/USM-281. with it are not required for the ripple voltage test.

(5) Dummy Load, Electrical DA-638/U. c. Initial Test Equipment Settings. Connect theb. Test Connections and Conditions. The test test equipment to the power source and allow a

procedures for performing the ripple voltage test are 10-minute warmup period before starting the to be performed with an input power source of 115 procedure in sub-paragraph d below.Vac/60 Hz and nominal power supply output

3-30

TM 11-6130-356-34

d. Procedure.

StepNo.

1

2

3

4

Control Settings

Test Equipment

AN/USM-223/U, ME-202( ) /U,and AN/USM-281:POWER. OFF

DA-638/U:Set for an AN/USM-223/Ureading of O amps. (Disconnectload if necessary. )

DA-638/U:Set for an AN/USM-223/Ureading of 10.0 ± 0.5 amps.AN/USM-223/U, ME-202( )/U,and AN/USM-281:POWER OFF

—


AC: OFFDC: OFF

VOLT SELECT 14V/28V:28VCURRENT RANGE: 10AC: ONDC: ON

Same as step No. 2.

DC: OFFAC: OFF

Test procedure

Connect the teat equipmentto the PP-6148/U as shownin figure 3-6.

Adjust VOLTAGE AD-JUST control for a readingon the ME-202( )/U of 28 ±0.1 V dc.

Same as step No. 2.

Disconnect all test equipment from the PP-6148/U.


None

AN/USM-281 displa-ys a maximum peak topeak ripple voltage of± 2% of 28.0 ± 0.1 vdc a n d t h eME-202( )/U displaysa maximum rmsvoltage of ± 1% of28.0 ± 0.1 V dc.Same as step No. 2.

None

3-24. Overload Protection and Current Landing standard ambient temperatures. The input power toTest

a Test Equipment and Materials.(1) Voltmeter, Electronic ME-202( )/U.(2) Ac power input cable.(3) Multimeter AN/USM-223/U.(4) Dummy Load, Electrical DA-638/U.

b. Test Connections and Conditions. The testprocedures for performing the overload protectionand current limiting test are to be performed under

the PP-6148/U should be 115 Vac/60 Hz. Upon com-pletion of the performance of the overload protec-tion and current limiting test, verify that no elec-trical damage may have occurred by performing theprocedures contained in paragraphs 3-21,3-22 and3-23. Figure 3-8 shows the test setup to be used forperforming the overload protection and currentlimiting test.

3-31

TM 11-6130-356-34

Figure 3-8. Overload Protection and Current Limiting Test Setup Diagram.

c. Initial Test Equipment Settings. Connect the minute warmup period before starting the procedure—test equipment to the power source and allow a 10- in subparagraph d below.

d. Procedure.

StepNo.

1

2

3

4

3-32

Control Settings

Test Equipment

AN/USM-223/U andME-202( )/U:POWER: OFFDA-638/U:Set for an AN/USM-223/Ureading of 5.0 ± 0.2 amps.

DA-638/U:Set for an AN/USM-223/Ureading of 10.0 ± 0.5 amps.Same as step No. 3.


AC: OFFDC: OFF

VOLT SELECT 14V/28V:28VCURRENT RANGE: 10VOLTAGE ADJUST:Set fully counterclockwise.CURRENT ADJUST(FINE): Set fully clockwise.AC: ONDC: ONSame as step No. 2

Same as step No. 2, exceptCURRENT RANGE: 8

Test procedure

Connect the test equipmentto the power supply asshown in figure 3-8.Rotate VOLTAGE AD-JUST control clockwise untilME-202( )/U indicates 28.0±0.l Vdc.

Same as step 2.

a. Rotate CURRENT AD-JUST (FINE) cont ro lcounterclockwise untilAN/USM-223/U indicates8.0 ± 0.4 amps.

b. Slowly rotate CURRENTADJUST (FINE) controluntil AN/USM-223/U in-dicates 4.0 ± 0.2 amps.


None

M E - 2 0 2 ( ) / U i n -dicates 28.0 ± 0.1 Vdc.

M E - 2 0 2 ( ) / U i n -dicates 28.0 ± 0.1 Vdc ± 1.5%.a. AN/USM-223/U in-

dicates 8.0 ± 0.4amps.

b. AN/USM-223/U in-dicates 4.0 ± 0.2amps.

TM 11--6130-356-34

d. Procedure-Continmd.

StepNo.

6

6

7

8

9

3-25.

(1)(2)(3)(4)(5)

( )/U.

Control Settings

Test EquipmentSame as step No. 3.

Same as step No. 3.

Same as step No. 3.

DA-638/U: Set for anAN/USM-223/U reading of ap-proximately 7 amps.

Equipment under testSame as step No. 2, exceptCURRENT RANGE: 4



Same as step No. 2, exceptDC: OFF and CURRENTRANGE: 10

AN/USM-223/U:POWER: OFF

Battery Discharging/Charging Test

DC: OFFAC: OFF

a. Test Equipment and Materials.Battery charger adapter cable.Ac power input cable.Multimetxer AN/USM-223/U (2 required).Voltmeter, Electronic ME-202( )/U.Battery, Vented Nickel-Cadmium BB-651

Test procedure Performance standarda. Rotate CURRENT AD- a AN/USM-2231U in-

JUST (FINE) control until dicates 2.0 ± 0.1AN/USM-223/U reads 2.0 amps.± 0.1 amps.

b. Rotate CURRENT AD- b. AN/USM-223/U in-JUST (FINE) control until dicates 4.0 ±0.2 am-AN/USM-223/U indicates p s .4.0 ±0.2 amps.

a.. Rotate CURRENT AD- a.. AN/USM-223/U in-JUST (FINE) control until dicates 2.0 ±O.1 am-AN/USM-223/U indicates ps.2,0 ±0.1 amps

b. Rotate CURRENT AD- b. AN/USM223/UJ in-JUST (FINE) control until dicates 1.0 ±0.05AN/USM-223/U indicates amps.1.0 ±0.05 amps.

a. Rotate CURRENT AD- AN/USM-223/U in-JUST (FINE) control until dicates 0.5 ±0.025AN/USM-223/U indicates0.6 ±0.026 amps.

b. Rotate CURRENT AD-JUST (FINE) control untilAN/USM-223/U indicates1.0 ±0.05 amps.

a. Set DC ON- OFF circuitbreaker to ON.

b. Slowly increase current byadjusting the DA-638/Uuntil the AN/USM-223/Uindicates 8.5 + 0. 5 -0.0amps

c. Continue adjusting theDA-638/U in the samedirection up to and in-cluding the short circuitcondition. Maintain theshort circuit condition for10 seconds, then removethe short.

Disconnect all test equip-ment from the PP-6148/U.

amps.

b. AN/USM-223/U in-dicates 1.0 ±0.05amps.

a. ME-202( )/U in-dicates 28.0 ±0.1 Vdc.

b. AN/USM-223/U in-dicates 8.5 + 0.5,

-0.0 amps.

c.. AN/USM-223/U in-dicates 13.0 ±1.0amps through outthe adustment up toand including theshort circuit con-dition; ME-202( )/U indicates 28.0±0.1 V dc ±1%when the short isremoved. In ad-dition, there shall beno evidence ofphysical damagethat might haveoccurred due tooverload conditions.

None.

(6) Dummy Load, Electrical DA-638/U (2required).

b. Test Connections and Conditions. The testprocedures f o r p e r f o r m i n g t h e b a t t e r ydischarging/charging test are to be performed understandard ambient temperatures. The input power tothe PP-6148/U should be 115 Vac/60 Hz. Figures3-9 and 3-10 show the test setups to be used for per-forming the battery discharging/charging test.

Change 1 3-33

TM 11-6130-356-34

Fgure 3-9. Battery Discharging/Charging Test Setup Diagram.

3-34

TM 11-6130-356-34

Figure 3-10. Battery Discharging Test Setup Diagram.

c. Initial Test Equipment Settings. Connect thetest equipment to the power source and allow a 10-minute warmup period before starting the procedurein subparagraph d below.

d. Procedure.

NOTEIn order to perform the battery chargingtest (step No. 4 thru 6 below), adischarged battery is required thatprovides 20 volts with a 10 ohm load con-nected to it. If such a battery is available,skip step No. 1,2 and 3 below.

CAUTIONDo not add electrolyte to the battery inthe discharged condition.

WARNINGExplosive gases may be released duringbattery charging operations. Be sure thatthe charging area is well ventilated. Donot use matches or an open flame in thecharging area. Guard against short cir-cuits; resulting arcs may cause an ex-plosion Do not disconnect the batterycharger adapter cable from the batteryuntil the DC ON-OFF circuit breaker isset to OFF, and the battery charger adap-ter cable is disconnected from the powersupply. Do not attempt to charge adamaged or leaking battery.

3-35

TM 11-6130-356-34

d. Procedure-Continued.

StepNo.

1

2

3

4

5

6

Control Settings

Teat EquipmentAN/USM-223/U, and ME-202( )/U:POWER: OFF

Set one AN/USM-223/U(marked #1) to the RX1 ohmsscale, and zero the meter asrequired.

Set AN/USM-223/U #l to ascale suitable for reading 20 Vdc.

Same as step No. 1,

115 Vac/60 Hz source.

Same as Step No. 5.

Equipment under testNone

None

None

AC: OFFDC: OFF

VOLT SELECT 14V/28V:28VCURRENT RANGE: 1VOLTAGE ADJUST: Setfully counterclockwise.CURRENT ADJUST(FINE): Set fully clockwiseAC: ONDC: ON

Same as step No. 5, exceptDC: OFF.

Test procedure Performance standard—Connect the test equipmentand battery to be dischargedas shown in figure 3-9(Battery Discharging Setup).Set toggle switch to openposition, and set oneDA-638/U (marked RL#l )for a reading onAN/USM-223/U #1 of 10ohms.

a.

b.

Set toggle switch toclosed position, and allowBB-651( )/U to dischargeuntil AN/USM-223/U #lindicates 20 Vdc (this willprobably take a few hoursto accomplish).Using the secondAN/USM-223/U (marked#2), measure voltage ofeach individual cell ofBB-651( )/U.

Set toggle switch to openposition.

c.

Connect the test equipmentto the PP-6148/U as shownin figure 3-9 (BatteryCharging Setup). Be surethat toggle switch is in openposition.a.

b.

a.

Rotate VOLTAGEADJUST controlclockwise untilME-202( )/U indicates29.5 V dc. Observe andnote the front panelOUTPUT meter voltagereading.Set toggle switch toclosed position, and setCURRENT ADJUST(FINE) control for anAN/USM-223/U readingof 1.0 amps. Hold theVOLTS/AMPS switch onPP-6148/U top panel inAMPS position, and notemeter reading.Disconnect ME-202( )/U,AM/USM-223/U, andDA-638/U fromPP-6148/U. Connectbattery charger adaptercable between battery tobe charged and dc outputconnec to r J2 onPP-6148/U. Set DC

None

AN/USM-223/U #lindicates 10 ohms.

a.

b.

AN/USM-223/U#1 indicates 20 Vdc.

AN/USM-223/U#2 indicates atleast 1.0 V dc foreach individual cellof BB-651( )/U. (Alower voltageindicates a badcell.)None

None

a. ME-202( )/U indi-cates 29.5 V dc.

b. AN/USM-223/Ureads 1.0 amps.

a. Top panel OUT-PUT meter in-dicates the samevoltage reading±1% as noted instep No. 5 a above,and indicates nomore than thecurrent reading as

3-36

TM 11-6130-356-34

d. Procedure- Continued.

No.6

(cont)

7

8

9

Control Settings

Test Equipment

AN/USM-223/U:POWER: OFF

AN/USM-2231U: Set up as amilliam-meter.

AN/USM-223/U, andME-202( )/UPOWER: OFF

Equipmentt under test

AC: OFFDC: ON

Same as step No. 7.

DC: OFFAC: OFF

b.

ON-OFF circuit breakerto ON, and observe toppanel OUTPUT meter.

. .Periodically disconnectthe battery from thebattery charger adaptercable, being sure to setDC ON-OFF circuitbreaker to OFF beforedoing so, and measure thebattery voltage.Charging is completedwhen battery voltagemeasures 24.0 V dc(approximately 8 hours).

Connect fully chargedbattery to PP-6148/U asshown in figure 3-10.a

b.

Observe current readingon AN/USM-223/U.

Reverse the leads at dcoutput connector J2 onPP-6148/U, and observecurrent reading onAN/USM-223/U.

Disconnect all test equip-ment and batteries from thePP-6148/U.

b.

noted in step No.5b above.

Battery voltagemeasures 24.0 V dcto indicate suc-cessful completionof batterycharging test .

None

Current reading onAN/USM-223/Udoes not exceed 50milliamps.Current reading onAN/USM-2231Udoes not exceed 50rnilliamps.

None

3-37

TM 11-6130-356-34

CHAPTER 4

GENERAL SUPPORT MAINTENANCE INSTRUCTIONS

Section I. GENERAL

4-1. General Support assembly A2. These additional procedures are

Maintenance of the PP-6148/U at the general sup- covered in paragraphs 4-2 through 4-5. Refer to

port level is the same as that for maintenance of the chapter 3, Direct Support Maintenance In-

PP-6148/U at the direct support level, except for structions, for all direct support information andprocedures that also apply to the general supportthe addition of repair Procedures for converter cir-

cuit card assembly A1Al and control

Section II.

4-2. General

circuit card level.

MAINTENANCE OF PP-6148/U

This section consists of removal and replacement in-structions and disassembly and reassembly in-structions applicable to the general support main-tenance level. Refe r to chap te r 3 , Di rec tSupport Maintenance Instruct ions, for ad-justment/alinement procedures, general partsreplacement techniques, removal and replacementinstructions, and disassembly and reassembly in-structions which are also applicable to the generalsupport maintenance level.

4-3. RepairLocate the defective component or part with the aidof the parts location illustrations: figure 3-3 forcover assembly Al, figure 3-5 for chassis-mountedcomponents, figure 4-1 for converter circuit cardassembly AlA1, and figure 4-2 for control circuitcard assembly A2.

4-4. Disassembly Instructions

Disassembly of the PP-6148/U at the general sup-port level involves converter circuit card assemblyAlAl and control circuit card assembly A2. Discon-nect the power source and set the AC and DCON/OFF switches to OFF before beginningdisassembly. Comply with precautionary in-structions to avoid injury to personnel and damjgeto equipment. Before disconnecting a component,tag and identify all its connecting leads, connecting.terminals or connecting points to facilitate recon-nection.

4-5. Removal, Disassembly and Reassembly ofConverter Circuit Card Assembly A1Al andControl Circuit Card Assembly A2

(fig. 4-1 and 4-2)

4-1

TM 11-6130-356-34

Figure 4-1. Converter Circuit Card Assembly (A1A1), Parts Location Diagram.

4-2 Change 1

TM 11-6130-356-34

Figure 4-2. Control Circuit Card Assembly (A2), Parts Location Diagram

Change 1 4-3

TM 11-6130-356-34

a Removal Remove cover assembly Al (3, fig.3-5) by loosening 14 captive screws(4).

b. Disassembly.(1) Disconnect leads and remove converter cir-

cuit card assembly AlA1 (1, fig. 3-3) by removingsix screws and twelve washers (2). Components ofconverter circuit card assembly A1A1 (fig. 4-1) areto be removed and replaced using standard shoptechniques.

(2) Disconnect, all leads from control circuitcard assembly A2 (6, fig. 3-5). Remove control cir-cuit card assembly A2 by removing two screws andmounting clips (7), and four screws and eightwashers (8). Components of control circuit cardassembly A2 (fig. 4-2) are to be removed andreplaced using standard shop techniques.

c. Reassembly.(1) Reinstall converter circuit card assembly

A1A1 (1, fig. 3-3) with six screws and twelvewashers (2). Reconnect leads.

(2) Reinstall control circuit card assembly A2(6, fig. 3-5) with two screws and mounting clips (7),and four screws and eight washers (8). Reconnectleads. Apply sealing compount MIL-S-22473 (item 1, appx B) to the two screws and mounting clips (7)after replacement.

(3) If previously removed, replace gasket (5) bycutting gasket 07-0101-004 (item 5, appx B) torequired length and affixing with adhesive 1711SCOTCH-GRIP (item 6, appx B). Replace coverassembly Al (3) by tightening 14 captive screws (4).

4-4

TM 11-6130-356-34

APPENDIX A

REFERENCES

The following list of references is applicable to Power Supply PP-6148/U:

DA Pam 310-4 Index of Technical Publications.SB 11-573 Painting and Preservation of Supplies Available for Field Use for

Electronic Command Equipment.TB 43-0118 Field Instructions for Painting and Preserving Electronics Command

Equipment Including Camouflage Pattern Painting of Electrical EquipmentShelters.

TB 43-180 Calibration Requirements for the Maintenance of Army Materiel.TM 11-6130-356-12 Operator’s and Organizational Maintenance Manual for Power Supply

PP-6148/U.TM 11-6130-356-20P Organizational Maintenance Repair Parts and Special Tools List for

Power Supply PP-6148/U.TM 11-6130-356-34P Direct Support and General Support Maintenance Repair Parts and

Special Tools List for Power Supply PP-6148/U.TM 11-6140 -203-14-3 Operator’s, Organizational, Direct Support, and General Support

Maintenance Manual: Nonaircraft Nickel-Cadmium Batteries.TM 38-750 The Army Maintenance Management System (TAMMS).TM 750-244-2 Procedures for Destruction of Electronics Materiel to Prevent

Enemy Use (Electronics Command).

A-1/(A-2 Blank)

TM 11-6130-356-34

APPENDIX B

EXPENDABLE SUPPLIES AND MATERIALS LIST

S e c t i o n I . I N T R O D U C T I O N

B-1. ScopeThis appendix lists expendable supplies andmaterials you will need to operate and maintain thePP-6148/U. These items are authorized to you byCTA 50-970, Expendable Items (Except Medical,Class V, Repair Parts, and Heraldic Items).

B-2. Explanation of Columnsa. Column 1—Item Number. This number is

assigned to the entry in the listing and is referencedin the narrative instructions to identify the material(e.g., "Use cleaning compound, item 5, App. D").

b. Column 2—Level This column identifies thelowest level of maintenance that requires the listeditem.

C–Operator/CrewO—Organizational MaintenanceF–Direct Support MaintenanceH—General Support Maintenance

c. Column 3—National Stock Number. This is theNational stock number assigned to the item; use itto request or requisition the item.

d. Column 4–Description Indicates the Federal

item name and, if required, a description to identifythe item. The last line for each item indicates thepart number followed by the Federal Supply Codefor manufacturer (FSCM) in parentheses, if ap-plicable.

e. Column 5— Unit of Measure (U/M). Indicatesthe measure used in performing by the actual main-tenance function. This measure is expressed a two-character alphabetical abbreviation (e.g., ea, in pr).If the unit of measure differs from the unit of issue,requisition the lowest unit of issue that will satisfyyour requirements.

B-3. Special InformationNational stock numbers (NSN’s) that are missingfrom section 11 have been applied for and will be ad-ded to this TM by future Change/Revision whenthey are entered in the Army Master Data File (AM-DF). Until the NSN’s are established and published,submit exception requisitions to Commander, USArmy Electronics Command, ATTN: DRSEL-MM,Fort Monmouth, NJ 07703 for the part required tosupport your equipment.

B-1/(B-2 BLank)

TM 11-6130-356-34

(i)ITEM

NO.

1

2

3

4

5

6

7

(2)LEVEL

F

F

F

F

F

F

F

(3)NATIONAL

STOCKNUMBER

8030-00-081-2330

6850-00-927-9461

8040-01-010-8758

5970-01-081-1733

5999-00-992-5541

SECTION II EXPENDABLE SUPPLIES AND MATERIALS LIST

(4)DESCRIPTION

PART NO. AND FSCM

SEALING COMPOUND, GRADE CV, MIL-S-22473 (81349)

GREASE, SILICONE, DC340-50Z (71984)

SEALING COMPOUND, RTV-732 (71984)

INSULATING COMPOUND, RTV-3140 (71984)

SHIELDING GASKET, ELECTRONIC, 07-0101-004 (12881)

ADHESIVE, SCOTCH-GRIP, 1711 (76381)

GASKET, R431N (82942)

(5)UNIT

OFMEAS

02

02

02

02

FT

FT

FT

B-3/( B-4 Blank)

U . S . G O V E R N M E N T P R I N T I N G O F F I C E 1 9 9 0 - 2 6 2 - 9 1 2 / 3 0 3 9 2

By Order of the Secretary of the Army

Official:ROBERT M. JOYCE

Brigadier General, United States ArmyThe Adjutant General

E. C. MEYERGeneral, United States Army

Chief of Staff

DISTRIBUTION:

To be distributed in accordance with Special Mailing List.

THE METRIC SYSTEM AND EQUIVALENTS

P I N : 0 5 1 0 5 0 - 0 0 1

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