4-254 Rev 16 Apr 2015

REVISION TRANSMITTAL
TO: HOLDERS OF COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST FOR
ELDEC 4-254-02, -03, AND -04 BATTERY CHARGER.
REVISION NUMBER 16, DATED APR 17/15

HIGHLIGHTS
The pages that have been revised, along with the highlights of the revision, are given below. Discard the
affected pages and replace with the revised pages.
Page No. Description of Change Effectivity
Title Page Updated. All

Record of Revisions Updated. All
Record of Temporary Updated. All
Revisions
List of Effective Pages Updated. All
Introduction
INT-1 Removed obsolete telephone number. All
This document contains data controlled by the EAR. Diversion or use contrary to U.S. law is prohibited.
Repair
6001 Added text “unless otherwise specified”. Changed High- All
Temp solder from SN96 Wrap 3 to Sn96.3Ag3.7.
Incorporated temporary revision TR 24-31-04-2.
6002 Updated Table 6001. Incorporated temporary revision All
TR 24-31-04-1.
Assembly
7002 Updated Table 7001 to add Solder. All
7007, 7012 Changed High-Temp solder from SN96 Wrap 3 to All
Sn96.3Ag3.7. Incorporated temporary revision
TR 24-31-04-2.
Special Tools, Fixtures,
and Equipment
9003 Updated Table 9002. All
HIGHLIGHTS
Page 1 of 1
24-31-04 Apr 17/15

CAGE: 08748
16700 13th Avenue West
Lynnwood, WA 98037-8503
Phone: +1-425-743-8662
Fax: +1-425-743-8113
BATTERY CHARGER
PART NO.
4-254-02/-03/-04
(BOEING S282T002-2/-4/-5/-6)
COMPONENT MAINTENANCE MANUAL

WITH
ILLUSTRATED PARTS LIST
CRANE AEROSPACE & ELECTRONICS PROPRIETARY

THE INFORMATION CONTAINED HEREIN IS PROPRIETARY TO CRANE AEROSPACE & ELECTRONICS AND SHALL
NOT BE REPRODUCED OR DISCLOSED IN WHOLE OR IN PART OR USED FOR ANY DESIGN OR MANUFACTURE
EXCEPT WHEN SUCH USER POSSESSES DIRECT WRITTEN AUTHORIZATION FROM CRANE AEROSPACE &
ELECTRONICS.
COMMERCIAL EXPORT ADMINISTRATION REGULATIONS (EAR)
THIS DOCUMENT CONTAINS DATA CONTROLLED BY THE U.S. EXPORT ADMINISTRATION REGULATIONS.
DIVERSION OR USE CONTRARY TO U.S. LAW IS PROHIBITED. ECCN: 9E991
T-1
Document No. CMM4-254 Revision 16
Initial Issue: Jan 25/82 24-31-04 Apr 17/15
4-254
BLANK
THIS PAGE
INTENTIONALLY
24-31-04
May 25/12
T-2
4-254
RECORD OF REVISIONS
Original Issue Date: Jan 25/82
REV ISSUE INSERT INSERTED REV ISSUE INSERT INSERTED

NO. DATE DATE BY NO. DATE DATE BY
1 Apr 30/82
2 Feb 15/84
3 Mar 15/86
4 Mar 31/88
5 Feb 15/89
6 Nov 1/90
7 Jan 30/92
8 Apr 15/97
9 Feb 15/98
10 Aug 2/99
11 May 18/01
12 Nov 15/01
13 May 25/12
14 Oct 5/12
15 Nov 14/14
16 Apr 17/15
Keep this record in front of the manual. When you get the revisions, put the
revised pages in the manual. Write the date inserted and initials on this page.
RECORD OF REVISIONS
ROR-1
24-31-04 Apr 17/15
4-254
BLANK
THIS PAGE
INTENTIONALLY
24-31-04 May 25/12

ROR-2
RECORD OF REVISIONS
4-254
RECORD OF TEMPORARY REVISIONS
TEMP INSERTED REMOVED

ISSUE INCORP.
REV
DATE DATE
NO. DATE BY DATE BY
24-31-04-1 Mar 12/15 Apr 17/15
24-31-04-2 Mar 12/15 Apr 17/15


RTR-1
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RTR-2
24-31-04 May 25/12
4-254
SERVICE BULLETIN LIST
Service Bulletins applicable to this manual are listed below. Service
Bulletins that affect this manual are shown by the date of incorporation.
SERVICE BULLETIN/ DATE BULLETIN

REVISION NUMBER
NUMBER INCORPORATED
4-254-24-09 1 Feb 15/89
4-254-24-10 0 Jun 15/91
4-254-24-11 1 Feb 1/95
4-254-24-12 2 Feb 12/97
4-254-24-13 2 Mar 30/04
PRODUCT IMPROVEMENT
Product improvements have been incorporated using service bulletins entered in the Service Bulletin List.
Service bulletin highlights are as follows:
Service Bulletin 4-254-24-09, Revision 1

This modification applies to Battery Charger PN 4-254-02 (Boeing ST282T002-2). It provides improved
performance and reliability at light dc loads (2A or less). In addition, the thermal interfaces of A3A1Q1 and
A3QA1U9 on the A3A1 card assembly are improved. Incorporation of this modification reidentifies the
Battery Charger as PN 4-254-03 (Boeing ST282T002-4).

This modification applies to Battery Charger PN 4-254-02 (Boeing ST282T002-2) or PN 4-254-03 (Boeing
ST282T002-4). These configurations have occasionally demonstrated premature termination of the charge
cycle caused by ac power interrupts during power transfer. The problem is corrected by reconnecting control
logic operating voltage on the A3A1 card assembly from the ac power derivative to the airplane battery bus.
Incorporation of this modification reidentifies the Battery Charger as follows:
From To
PN 4-245-02 (08748-4-254-02) PN 4-254-02 Mod 1 (08748-4-254-02 Mod 1)
Boeing ST282T002-2 Boeing ST282T002-5
PN 4-245-03 (08748-4-254-03) PN 4-254-04 (08748-4-254-04)
Boeing ST282T002-4 Boeing ST282T002-6

This modification applies to Battery Charger, ELDEC Part Number 4-254, Serial Number 2865 through 3883
and 3886 and 3887. This modification corrects a vendor part manufacturing error regarding the Terminal
Block Assembly (A5), IPL Figure 1 item 105. This vendor terminal block is constructed using mild steel studs
instead of the required stainless steel studs. The mild steel studs can rust. Incorporation of this modification
installs a replacement Terminal Block Assembly constructed with stainless steel studs, thereby bringing the
unit into compliance with ELDEC specifications and drawings. There is no part number change because this
was a manufacturing defect of the required part. The item only needs to be replaced with the correctly
manufactured item.

SBL-1
24-31-04 May 25/12
4-254
This bulletin corrects a condition that could lead to possible failure of switching transistors Q1 and Q2. The
failure may be caused by foreign metallic debris and/or liquid accumulation between the upper installation
hardware for the transistors and the transistor case. Incorporation of this bulletin replaces a washer and adds
silicone sealant that fills the void between the washer and the transistor case. This modification changes
usage of IPL Figure 1 item 1-357, Part number AN960-C4, to IPL Figure 1, item 357A, Part Number
NAS620C5.

This service bulletin applies to ELDEC Part Number 4-254-02, 4-254-02 Mod 1, 4-254-03 and 4-254-04
Battery Chargers. Affected serial numbers are: 4500 and below. Affected old assembly is 4-254324-01. This
modification improves the reliability of the Battery Charger by replacing the output power rectifiers A4A1CR1
and A4A1CR2, IPL Figure 1 item 495, Part Number UTG5140, with rectifiers of a higher voltage rating,
IPL Figure 1 item 495A, Part Number UTG8187.

SBL-2
24-31-04 May 25/12
4-254
LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE PAGE DATE PAGE DATE PAGE DATE
TITLE T-1 Apr 17/15 T-2 Blank
RECORD OF ROR-1 Apr 17/15 ROR-2 Blank

REVISIONS
RECORD OF RTR-1 Apr 17/15 RTR-2 Blank

TEMPORARY
REVISIONS
SERVICE BULLETIN SBL-1 May 25/12 SBL-2 May 25/12

LIST
LIST OF EFFECTIVE LEP-1 Apr 17/15 LEP-2 Apr 17/15 LEP-3 May 25/12 LEP-4 Blank
PAGES
TABLE OF CONTENTS TOC-1 May 25/12 TOC-2 May 25/12 TOC-3 May 25/12 TOC-4 May 25/12
LIST OF FIGURES LOF-1 May 25/12 LOF-2 Blank
LIST OF TABLES LOT-1 May 25/12 LOT-2 Blank
INTRODUCTION INT-1 Apr 17/15 INT-2 May 25/12

DESCRIPTION AND 1 Oct 5/12 8 May 25/12 15 May 25/12 22 May 25/12
OPERATION 2 May 25/12 9 May 25/12 16 May 25/12 23 May 25/12
3 May 25/12 10 May 25/12 17 May 25/12 24 May 25/12
4 May 25/12 11 May 25/12 18 May 25/12 25 May 25/12
5 May 25/12 12 May 25/12 19 May 25/12 26 May 25/12
6 May 25/12 13 May 25/12 20 May 25/12 27 May 25/12
7 May 25/12 14 May 25/12 21 May 25/12 28 May 25/12
TESTING AND FAULT 1001 Nov 14/14 1009 May 25/12 1017 May 25/12 1025 May 25/12
ISOLATION 1002 May 25/12 1010 May 25/12 1018 May 25/12 1026 May 25/12
1003 May 25/12 1011 May 25/12 1019 May 25/12 1027 May 25/12
1004 May 25/12 1012 May 25/12 1020 May 25/12 1028 May 25/12
1005 May 25/12 1013 May 25/12 1021 May 25/12 1029 May 25/12
1006 May 25/12 1014 May 25/12 1022 May 25/12 1030 May 25/12
1007 May 25/12 1015 May 25/12 1023 May 25/12 1031 May 25/12
1008 May 25/12 1016 May 25/12 1024 May 25/12 1032 May 25/12
SCHEMATICS AND 2001 May 25/12 2009 Blank 2017 Blank 2025 Blank
WIRING DIAGRAMS 2002 May 25/12 2010 May 25/12 2018 May 25/12 2026 May 25/12
2003 May 25/12 2011 May 25/12 2019 May 25/12 2027 May 25/12
2004 Blank 2012 Blank 2020 Blank 2028 Blank
2006 May 25/12 2014 May 25/12 2022 May 25/12 2030 May 25/12
2007 May 25/12 2015 May 25/12 2023 May 25/12 2031 May 25/12

LEP-1
24-31-04 Apr 17/15
4-254
DISASSEMBLY 3001 May 25/12 3002 May 25/12 3003 May 25/12 3004 May 25/12
CLEANING 4001 Nov 14/14 4002 Blank
REPAIR 6001 Apr 17/15 6008 May 25/12 6015 May 25/12 6022 May 25/12
6002 Apr 17/15 6009 May 25/12 6016 May 25/12 6023 May 25/12
6003 Apr 17/15 6010 May 25/12 6017 May 25/12 6024 May 25/12
6004 May 25/12 6011 May 25/12 6018 May 25/12 6025 May 25/12
6005 May 25/12 6012 May 25/12 6019 May 25/12 6026 Blank
6006 May 25/12 6013 May 25/12 6020 May 25/12
6007 May 25/12 6014 May 25/12 6021 May 25/12
ASSEMBLY 7001 May 25/12 7005 May 25/12 7009 May 25/12 7013 May 25/12
7002 Apr 17/15 7006 May 25/12 7010 May 25/12 7014 May 25/12
7003 Apr 17/15 7007 Apr 17/15 7011 May 25/12
7004 Apr 17/15 7008 May 25/12 7012 Apr 17/15
FITS AND 8001 May 25/12 8002 Blank

CLEARANCES
SPECIAL TOOLS, 9001 Nov 14/14 9003 Apr 17/15 9005 May 25/12
FIXTURES AND 9002 Oct 5/12 9004 Apr 17/15 9006 Blank
EQUIPMENT
ILLUSTRATED PARTS 10001 May 25/12 10025 May 25/12 10049 May 25/12 10073 May 25/12
LIST 10002 May 25/12 10026 May 25/12 10050 May 25/12 10074 May 25/12
10003 Nov 14/14 10027 May 25/12 10051 May 25/12 10075 May 25/12
10004 Oct 5/12 10028 May 25/12 10052 May 25/12 10076 May 25/12
10005 Oct 5/12 10029 May 25/12 10053 May 25/12 10077 May 25/12
10006 May 25/12 10030 May 25/12 10054 May 25/12 10078 May 25/12
10007 May 25/12 10031 May 25/12 10055 May 25/12 10079 May 25/12
10008 May 25/12 10032 May 25/12 10056 May 25/12 10080 May 25/12
10009 May 25/12 10033 May 25/12 10057 May 25/12 10081 May 25/12
10010 May 25/12 10034 May 25/12 10058 Blank 10082 May 25/12
10011 May 25/12 10035 May 25/12 10059 May 25/12 10083 May 25/12
10012 May 25/12 10036 May 25/12 10060 May 25/12 10084 May 25/12
10013 May 25/12 10037 May 25/12 10061 May 25/12 10085 Blank
10014 May 25/12 10038 May 25/12 10062 May 25/12 10086 May 25/12
10015 May 25/12 10039 May 25/12 10063 May 25/12 10087 May 25/12
10016 May 25/12 10040 May 25/12 10064 May 25/12 10088 May 25/12
10017 May 25/12 10041 May 25/12 10065 May 25/12 10089 May 25/12
10018 May 25/12 10042 May 25/12 10066 May 25/12 10090 May 25/12
10019 May 25/12 10043 May 25/12 10067 May 25/12 10091 May 25/12
10020 May 25/12 10044 May 25/12 10068 May 25/12 10092 May 25/12
10021 May 25/12 10045 May 25/12 10069 May 25/12 10093 May 25/12
10022 May 25/12 10046 May 25/12 10070 May 25/12 10094 May 25/12
10023 May 25/12 10047 May 25/12 10071 May 25/12 10095 May 25/12
10024 May 25/12 10048 May 25/12 10072 May 25/12 10096 May 25/12

LEP-2
24-31-04 Apr 17/15
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10097 May 25/12 10104 May 25/12 10111 May 25/12 10118 Blank
10098 May 25/12 10105 May 25/12 10112 May 25/12 10119 May 25/12
10099 May 25/12 10106 May 25/12 10113 May 25/12 10120 May 25/12
10100 May 25/12 10107 May 25/12 10114 May 25/12 10121 May 25/12
10101 May 25/12 10108 May 25/12 10115 May 25/12 10122 May 25/12
10102 May 25/12 10109 May 25/12 10116 May 25/12
10103 May 25/12 10110 May 25/12 10117 May 25/12

LEP-3
24-31-04 May 25/12
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LEP-4
24-31-04 May 25/12
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TABLE OF CONTENTS
PARAGRAPH/TITLE PAGE
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Transformer Rectifier (TR) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Charge Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Low Current Operation, 4-254-03 and -04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
E. Shutdown (Figure 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F. Excessive Charge Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2. Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
A. Outline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
B. Input Power Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
C. Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
D. Power Output Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
E. Control and Protection Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
G. Inverter Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
H. TR Mode (Constant Voltage) Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
I. Low Output Current Operation (A3A2) (4-254-03/-04 only) . . . . . . . . . . . . . . . . . . . . . . . . 27
TESTING AND FAULT ISOLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001

1. Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
A. Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
B. Pre-Performance Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1005

C. Performance Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1007
2. Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1018
A. Fault Isolation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1018
B. Fault-Isolation Chart Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1018
C. Schematics and Circuit Function Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1018
D. Preparation of Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1018
E. Optional Circuit Board Breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1019
SCHEMATICS AND WIRING DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2001

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2001
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001
2. Specific Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001
2. Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001
A. Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001
REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001
A. General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001
B. General Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001
2. Materials and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6002
A. Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6002
TABLE OF CONTENTS
TOC-1
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TABLE OF CONTENTS
B. Tools Necessary for Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6003
3. Special MOS Device Handling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6004
4. CCA Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6005
A. CCA Laminate Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6005
B. Lifted Circuit Pads or Traces Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6005
C. Missing Pad Repair (Connected to Trace) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6006
D. Missing Pad Repair (Not Connected to Trace) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6006
E. Epoxy Bond Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6007
F. Epoxy Bond Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6007
G. Conformal Coating Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6007
H. Conformal Coating Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6008
5. Component Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6008
A. Plated Through-Hole Component Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6008
B. Plated Through-Hole Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6008
6. A5A1 Filter Cap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6009
A. C1, C2, and C3 Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6009
7. A4 Left Heat Sink Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6009
A. C1 and C2 Capacitor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6009
8. A4A1 Output Diode Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6010
A. C3 Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6010
9. Snubber Output Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6010
B. R1 and R2 Resistor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6010
10. A1 Input Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6010

11. A1A2 Circuit Card Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6011
B. C3 thru C8 Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6011
12. A1A1 Capacitor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6012
A. R4 Resistor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6013
B. C14 Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6013
C. C29 and C30 Capacitor Replacement (4-254253-01, -02, -03, -04,
4-254453-02, and -04 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6014
D. C31 and C32 Capacitor Replacement (4-254253-02, 4-254453-02, and -04 only). . . . 6014
E. R87 Resistor Replacement (4-254353-03, -04, 4-254453-03, -04, and
4-254553-02 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6014
F. J1 Connector Replacement (4-254353-01, -02, -03, -04, 4-254453-01, -03,
4-254553-01, and -02 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6014
G. J1 Connector Replacement (4-254253-01, -02, -03, -04, 4-254453-02, and -04 only) . 6015
H. Q2 thru Q8, Q10, and Q11 Transistor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 6015
I. U1 thru U8 Microcircuit Replacement (except 4-254553-01 and -02) . . . . . . . . . . . . . . 6015
J. R1 Resistor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6015
A. C25 Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6016
B. C31 Capacitor Replacement (4-254255-01, -02, and 4-254655-03 only) . . . . . . . . . . . 6016
C. R48, R51, R54, R64, and R67 Resistor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 6016
D. C33 Capacitor Replacement (4-254255-02 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6017
TABLE OF CONTENTS
TOC-2
24-31-04 May 25/12
4-254
TABLE OF CONTENTS
E. R92 Resistor Replacement (4-254255-02 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6017
F. C10 Capacitor Replacement (4-254455-01 and 4-254655-02 only) . . . . . . . . . . . . . . . . 6017
G. R94 Resistor Replacement (4-254655-01, -02, and -03 only) . . . . . . . . . . . . . . . . . . . . 6018
H. C39 Capacitor Replacement (4-254655-01, -02, and -03 only) . . . . . . . . . . . . . . . . . . . 6018
I. Res, Cap, Diode Network Replacement (4-254655-01, -02, and -03 only). . . . . . . . . . . 6019
J. C37 and C38 Capacitor Replacement (4-254655-02 and -03 only) . . . . . . . . . . . . . . . . 6019
K. C34 and C35 Capacitor Replacement (4-254655-03 only) . . . . . . . . . . . . . . . . . . . . . . . 6019
L. J1 Connector Replacement (4-254455-01, 4-254555-01, 4-254655-01, -02,
and 4-254755-01 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6020
M. J1 Connector Replacement (4-254255-01, -02, and 4-254655-03 only). . . . . . . . . . . . . 6020
N. Q1 thru Q6, Q8, Q12, and Q17 thru Q20 Transistor Replacement. . . . . . . . . . . . . . . . . 6020
O. Q7, Q9 thru Q11, and Q13 thru Q16 Transistor Replacement . . . . . . . . . . . . . . . . . . . . 6021
P. U1, U3 thru U8 Microcircuit Replacement (except 4-254755-01) . . . . . . . . . . . . . . . . . . 6021
Q. R49 and R62 Resistor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6021
15. A2A1 Circuit Card Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6021
A. C1 and C2 Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6021
B. T1 and T4 Transformer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6022
C. Jumper Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6022
D. P1 Connector Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6025
E. T2 and T3 Transformer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6025
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001
2. Recommended Materials, Tools, fixtures and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001

3. Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7002
4. Mounting Details for Insulated Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7004
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7004
B. Transistors A2Q1/A2Q2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7004
C. Transistor A3A1Q1 and Voltage-Regulator Microcircuit A3A1U9 . . . . . . . . . . . . . . . . . . 7008
5. Replacement and Installation of Circuit Card Assy A2A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7010
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7010
B. A2A1 Circuit Card Assy Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7011
C. A2A1 Circuit Card Assy Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7012
6. Installation of Diode A1CR1 and A1 Input Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7013
A. Installation of Diode A1CR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7013
B. Installation of A1 Input Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7013
FITS AND CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001
2. Fastener Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001
2. Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001
3. Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003
TABLE OF CONTENTS
TOC-3
24-31-04 May 25/12
4-254
TABLE OF CONTENTS
ILLUSTRATED PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10001
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10001
A. Figure and Item Number Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10001
B. Part Number Column. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10001
C. Airline Part Number Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10001
D. Nomenclature Column. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10001
E. Effectivity Code Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10002
F. Units Per Assembly Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10002
2. Vendors Code, Name and Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10002
3. Equipment Designator Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10002
4. Numerical Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10002
TABLE OF CONTENTS
TOC-4
24-31-04 May 25/12
4-254
LIST OF FIGURES
FIGURE NO./TITLE PAGE
DESCRIPTION AND OPERATION

Figure 1 Battery Charger Block Diagram (4-254-02). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 2 T-R Mode Voltage-Current Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 3 Change Mode Voltage-Current Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 4 Charge Mode Charge Cycle Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 5 Protection Circuits Block Diagram (4-254-02). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 6 Charge Control Circuits Block Diagram (4-254-02). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 7 Inverter Control Waveform Relationships . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TESTING AND FAULT ISOLATION

Figure 1001 Variable Resistive Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1003
Figure 1002 Reverse Current Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1006
Figure 1003 Battery Charger Test Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1008
Figure 1004 Fault Isolation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1020
SCHEMATICS AND WIRING DIAGRAMS

Figure 2001 4-254-02/-02 MOD1 Battery Charger Schematic/Wiring Diagram . . . . . . . . . . . . . . . . . 2002
Figure 2002 4-254-03/-04 Battery Charger Schematic/Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . 2018
DISASSEMBLY
Figure 3001 Input Assembly A1, Detail of A1CR1 (part of 4-254301). . . . . . . . . . . . . . . . . . . . . . . . . 3004
REPAIR
Figure 6001 C1 thru C8 Capacitor Replacement (A1A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6012
Figure 6002 C1, C2, and C3 Capacitor Replacement (A1A1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6013
Figure 6003 C10 Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6018
Figure 6004 Wire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6024
ASSEMBLY
Figure 7001 Heat Sink Counterbore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7006

IPL Figure 1 Battery Charger Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10035
IPL Figure 2 Input Assembly A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10054
IPL Figure 3 Circuit Card Assembly A3A1 (Configuration 4-254253-01/-02/-03/-04) . . . . . . . . . . . . 10059
IPL Figure 4 Circuit Card Assembly A3A2 (Configuration 4-254255-01/-02) . . . . . . . . . . . . . . . . . . 10086
IPL Figure 5 Circuit Card Assembly A2A1 (Configuration 4-254311-01). . . . . . . . . . . . . . . . . . . . . . 10119
LIST OF FIGURES
LOF-1
24-31-04 May 25/12
4-254
BLANK
THIS PAGE
INTENTIONALLY
24-31-04May 25/12
LOF-2
LIST OF FIGURES
4-254
LIST OF TABLES
TABLE NO./TITLE PAGE

Table 1 Leading Particulars Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Table 1001 Equipment Necessary for Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
Table 1002 Variable Resistive Load Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1004
Table 1003 Insulation Resistance Test Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1005
CLEANING
Table 4001 Cleaning Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001
REPAIR
Table 6001 Materials Necessary for Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6002
Table 6002 Tools Necessary for Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6003
Table 6003 Wire Connection Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6022
ASSEMBLY
Table 7001 Materials Necessary for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001
FITS AND CLEARANCES

Table 8001 Battery Charger Fastener Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT

Table 9001 Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001
Table 9002 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003
LIST OF TABLES
LOT-1
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BLANK
THIS PAGE
INTENTIONALLY
24-31-04
May 25/12
LOT-2
LIST OF TABLES
4-254
INTRODUCTION
CAUTION: UNLESS OTHERWISE NOTED, ALL INTEGRATED CIRCUITS ON CIRCUIT CARDS

ARE CMOS AND REQUIRE SPECIAL STATIC HANDLING PRECAUTIONS.
NOTE: All voltages are dc unless otherwise stated.
This manual gives the instructions to do a simple repair or a complete overhaul. These instructions do
not give all details and do not identify all differences in equipment. For more data or if a problem cannot
be corrected through the use of these instructions, contact:
Product Support Representative

Crane Aerospace & Electronics
ELDEC Corporation
16700 13th Ave. West
Lynnwood, WA 98037-8503
U.S.A.
Telephone: +1-425-743-8272
+1-425-743-8473
Facsimile: +1-425-743-8371
Internet: http://www.craneae.com
Email: info@craneae.com
To ask other questions or make comments about this document, please contact Technical Publications
at http://www.craneae.com/CustomerService/TechPubComments.aspx.
The use of Warnings, Cautions and Notes in this manual are defined as follows:
WARNING: WARNINGS IDENTIFY MATERIALS, PROCESSES, METHODS, PROCEDURES, OR

LIMITS THAT CAN CAUSE INJURY TO PERSONS.
CAUTION: CAUTIONS IDENTIFY METHODS AND PROCEDURES THAT CAN CAUSE DAMAGE
TO EQUIPMENT.
NOTE: Notes identify or add important data.
Warnings and Cautions are located directly above the data to which they apply. Notes follow the data to
which they apply.
Use of the Illustrated Parts List is explained in an introduction to that section.
Verification:
Testing and Fault Isolation Verified 12/15/00

Disassembly Verified 12/3/81
Assembly Verified 5/18/01
Acronyms and abbreviations are listed on the next page.
INTRODUCTION
INT-1
24-31-04 Apr 17/15
4-254
ACRONYMS AND ABBREVIATIONS

ACRONYM ASSIGNED MEANING ACRONYM ASSIGNED MEANING
A amperes < less than
ac alternating current > greater than
AWG Average Wire Gauge  less than or equal to
BKDN Breakdown  greater than or equal to
C Celsius ± plus/minus
CCA Circuit Card Assembly  ohms
CMM Component Maintenance Manual
dc direct current
DEL Delete
EICAS Engine Indications and Crew Alert
System
ESD Electrostatic Discharge
ESDS Electrostatic Discharge Sensitive
F Fahrenheit, Farad
Fig. Figure
g gram
h henry
Hz Hertz
ID Inside Diameter
IPL Illustrated Parts List
k Kilo
lb-in pounds per inch
LED Light Emitting Diode

m milli
mm millimeter
M Mega
MOS Metal Oxide Semiconductor
N-m Newton per millimeter
OD Outside Diameter
PN Part Number
PWB Printed Wire Board
PWM Pulse Width Modulator
p-p peak to peak
REPLD Replaced
REPLS Replaces
RF, ref reference
rms root mean square
s seconds
SMT Surface Mount Technology
SPST Single Pull Single Throw
SUPSDS Supersedes
SUPSD Superceded
TFE Teflon
TR Transformer Rectifier
V Volts
VWA Volt Watts Amps
W Watts
 micro
INTRODUCTION
INT-2
24-31-04 May 25/12
4-254
1. Description
A. General
The 4-254-02 (Boeing S282T002-2), 4-254-03 (S282T002-4) and 4-254-04 (S282T002-6) Battery
Chargers are packaged in an ARINC 600 6MCU outline. The left and right sides are externally
finned heat sinks. There is a dc power output connection (5/16” negative (-) and 3/8” positive (+)
terminals) and cable connector (for ac input power, control and sense) on the front panel. The unit
may be convection cooled (up to 50 A load current), or forced air cooled with 75 pound (34 kg) /
hour air (up to 60A load current).
The charger operates with 105 to 122 Vrms, 400 Hz, 3 phase input voltage. It provides an output of
up to about 36 V dc at a constant 38 A or an output of a constant 27.75 V dc, depending on mode
of operation. The charger operates either in a transformer-rectifier mode or a charge mode.
The Battery Charger Schematic Diagrams are provided in the Schematics and Wiring section,
Figure 2001 (4-254-02 and -02 MOD1) or Figure 2002 (4-254-03 and -04). The overall block
diagram is shown in Figure 1.
B. Transformer Rectifier (TR) Mode
In the TR mode the output is 27.75 V dc, constant voltage, at up to 64 A. This voltage will maintain
the battery charge without unnecessary electrolyte loss. The current will be provided to an aircraft
load. The output Voltage-Current characteristics for the TR mode are shown in Figure 2.
C. Charge Mode
The charge mode is commanded when J1 pin 8 is connected to the output negative terminal.
In the charge mode the Battery Charger initiates a battery charge cycle in a constant current
mode (until completion of charge). The output voltage will vary with battery state-of-charge and
load resistance; initially, it will be about 28 V dc and the current will remain constant at about 38 A.
The output Voltage-Current characteristics for the charge mode are shown in Figure 3.
Page 1
24-31-04 Oct 5/12
OUTPUT VOLTAGE
INPUT CURRENT OUTPUT

INPUT POWER TRANSFORMER OUTPUT
INPUT AC FILTER SENSE INVERTER
FILTER RECTIFIER AND FILTER
POWER TRANSFORMER
RECTIFIER
CIRCUIT
BASE DRIVE
POWER
TRANSFORMER
TRANSFORMER
CIRCUIT
POWER BATTERY
RECTIFIER
A1 A2 A4 A5
A3A1
CHARGE CYCLE INITIATOR

23V (REF)
OFF PULSE TEMP SENSOR
A3A2
CONTROL CHARGE
CYCLE
TEMP SENSOR RETURN
CONTROL
CURRENT
SENSE BASE DRIVE BASE DRIVE
10%
4-254
FILTER LOGIC CIRCUIT

OVER-CHARGE
FAULT FAULT TEMP ANNUNCIATION

CURRENT CURRENT THERMAL
LIMIT SENSOR SWITCH
LIMIT INTERLOCK
Figure 1 (Sheet 1 of 2)
PWM
SHUTDOWN
PROTECTION ANNUNCIATOR TO INPUT
CIRCUIT POWER
70A (REF)
RELAY
Battery Charger Block Diagram (4-254-02)

CURRENT CIRCUITS
PWM SOFT START
REGULATOR
24-31-04
+20VDC +5VDC
MODE
CONTROL
CONSTANT 5 VDC
CURRENT 20 VDC
VOLTAGE CURRENT
ORDER REGULATOR
OVERRIDE AMPLIFIER
CONSTANT V COMPTR
27.75V (REF) 5V (REF)
4-254_V0011_EX-FIG 1
May 25/12
Page 2
OUTPUT VOLTAGE
INPUT OUTPUT
INPUT CURRENT
POWER FILTER INVERTER TRANSFORMER OUTPUT
INPUT AC SENSE
FILTER AND FILTER
POWER RECTIFIER TRANSFORMER
RECTIFIER
CIRCUIT
BASE DRIVE
POWER
TRANSFORMER
TRANSFORMER
CIRCUIT
POWER
RECTIFIER BATTERY
A1 A2 A4 A5
A3A1
A3A2 CHARGE CYCLE INITIATOR
23V (REF)
TEMP SENSOR
CHARGE
CYCLE
CONTROL TEMP SENSOR RETURN
CURRENT
BASE DRIVE BASE DRIVE
SENSE 10%
LOGIC CIRCUIT
FILTER OVER-CHARGE
FAULT FAULT ANNUNCIATION
CURRENT CURRENT TEMP THERMAL
4-254
LIMIT LIMIT SENSOR INTERLOCK SWITCH

PWM
SHUTDOWN
PROTECTION
ANNUNCIATOR TO INPUT
CIRCUIT
70A (REF) POWER
RELAY
CURRENT CIRCUITS
PWM SOFT START
REGULATOR
MODE +20VDC +5VDC

CONTROL
Battery Charger Block Diagram (4-254-03/-04)

CONSTANT 5 VDC
CURRENT 20 VDC
VOLTAGE CURRENT
ORDER REGULATOR
24-31-04
OVERRIDE AMPLIFIER
27.75V (REF) 5V (REF)
HYSTERESIS CONSTANT V
SHUTDOWN AMPLIFIER/COMPARATOR
4-254_V0012_EX-FIG 1
VOLTAGE LOOP
COMPENSATION
May 25/12
Page 3
4-254
Figure 2
T-R Mode Voltage-Current Curve
24-31-04
Page 4
May 25/12
4-254
Figure 3
Change Mode Voltage-Current Curve
24-31-04
May 25/12
Page 5
4-254
As the battery state-of-charge increases, the output voltage rises to the inflection point (about
31 V dc), continues rising until proportionate overcharge is completed, then drops to 27.75 V dc.
After this drop the charger is in the constant voltage mode. This function is shown in Figure 4.
NOTE: The duration of the proportionate overcharge is 5% of the base charge time in the
standard application. In the special 757 application a jumper installed between J1 Pin 5
and J1 Pin 6 causes the overcharge time to be 10% of the base charge time (12% for
charger serial number 232 and subsequent).
In the constant voltage mode, as the load resistance at the output varies, the output current may
vary up to 38 A, but the output voltage remains constant at 27.75 V dc. If the effective load
resistance reduces enough to attempt to draw > 38 A, the voltage reduces but the charger is able
to maintain the 38 A until the output voltage reduces to about 20 V dc; then the output current
capacity reduces. The charger shuts down when the output voltage reaches 4 V dc.
The Battery Charger will initiate a new charge cycle starting with base charge, when one of the
following occurs:
(1) AC input power is applied, or is reapplied after an interruption of > 500 ms time, or
(2) Sensed battery voltage drops below 23 V dc, or
(3) The charger is switched to the Charge Mode after > 500 ms in the TR Mode.
D. Low Current Operation, 4-254-03 and -04

When the model 4-254-03 & -04 Battery Charger is operating in the constant voltage mode and at
low current below approximately 3 A, the Battery Charger operates in a hysteresis type mode.
The charger shuts down and restarts with a cyclic operation. The battery voltage changes in a
sawtooth fashion by only 100 mVp-p. The period of this off-on operation varies, but is
approximately 10s. The actual period depends upon battery condition and load.
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4-254
Figure 4
Charge Mode Charge Cycle Curve
24-31-04
May 25/12
Page 7
4-254
E. Shutdown (Figure 5)
The Battery Charger will shutdown under the following conditions:
• Battery power connector off when power applied (or shop test external power supply
connected to power terminals, below 4.0 V dc) (not annunciated)
• Battery interlock (sense and control cable not connected to a battery) (annunciated *)
• Input voltage over 130 Vrms/under 94 Vrms (not annunciated)
• Overcurrent (not annunciated)
• Battery overtemperature (annunciated *)
• Loss of input power (annunciated *)
* The charger shutdown annunciator transistor (A3A1 Q2) switches the shutdown
annunciation signal (negative output terminal to J1 Pin 9) to aircraft annunciation
circuits when Battery Interlock, loss of Input Power, or Battery Overtemperature
shutdown occurs.
Under normal operation the Q2 switch conducts from the negative output terminal, through a
current limiting 10 ohm resistor in the Battery Charger, and through an aircraft annunciation
control circuit, which drives the aircraft Battery System Monitor and EICAS.
When a fault to be annunciated occurs, the transistor switch A3A1 Q2 is cut off, providing an open
circuit at the Battery Charger shutdown annunciation output (A6J1 Pin 9). The shutdown LED
comes on.
NOTE: An annunciation will also occur when there is no ac input power to the Battery Charger;
i.e., Circuit breaker open, etc. When the charger is not powered, A3A1 Q2 cannot
conduct.
(1) Power Connector Disconnect
No shutdown occurs if the power connector is disconnected from the battery during system
operation. If the system was in a charge cycle in the charge mode, the charger output
voltage will reach the inflection point quickly (unless an aircraft load exceeds 38 A) and the
output will be a constant voltage (27.75 V dc) supplying current to an aircraft system load. In
the TR mode, the charger will simply continue as it was, supplying up to 64 A current to a
system load at 27.75 V dc.
However, if the battery power connector is not connected at the time the Battery Charger
system is energized, the charger will not start. The Battery Charger cannot start unless the
voltage sensed at the output terminals is above approximately 4 V dc.
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4-254
Protection Circuits Block Diagram (4-254-02)
Page 9
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4-254
Protection Circuits Block Diagram (4-254-03/-04)
Page 10
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4-254
(2) Sense Connector Disconnect
When the interconnecting sense and control cable between the Battery Charger and the
battery is not connected to the battery, an open circuit in the battery interlock circuitry
sensed at A6J1 Pins 1 and 3 will cause system shutdown and annunciation. The system will
return to normal operation when this cable is reconnected; therefore, no resetting is
necessary, unless the battery power connector is also disconnected.
(3) Overvoltage/Undervoltage
Although the Battery Charger will shutdown when the ac input is over or undervoltage, the
system will return to normal operation 10 to 25 seconds after an overvoltage condition
clears. It will return to normal immediately when an undervoltage condition clears.
(4) Overcurrent
An internally caused overcurrent condition or inverter circuit unbalance causes a cyclic

shutdown/soft start operation. The overcurrent shutdown signal has a fixed time duration,
and when it clears, a soft start is applied to the inverter. The cyclic shutdown/soft start will
repeat as long as an overcurrent condition or inverter circuit unbalance is present. (Under
proper operation, the output current is limited to 38 A or 64 A (depending on mode) with no
cyclic shutdown, regardless of output load condition.)
(5) Overtemperature
A battery temperature of 145 °F (62.8 °C) or above will cause the Battery Charger to
shutdown, but when the battery cools to about 135 °F (57.2 °C) (5 to 15 °F (2.8 to 7.8 °C)
below shutdown temperature)) the system will return to normal operation.
(6) Loss of Input Power
Loss of ac input power prevents A3A1 Q2 from conducting, which causes a fault indication,
although no failure may be occurring in the battery/Battery Charger system. (Low input
voltage or an open ac input phase causes a Battery Charger shutdown that is not
annunciated.)
F. Excessive Charge Time
The normal fully discharged battery completely recharges within approximately 75 minutes. If the
charge command continues beyond this maximum recharge time and approaches 100 minutes,
the unit will switch into the constant voltage mode of operation, stopping the constant current
charge.
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4-254
2. Theory of Operation
A. Outline
The outline of the theory of operation contained herein is as follows:
A Outline
B Input Power Circuit
C Inverter
D Power Output Section
E Control and Protection Circuits

(1) Control Circuit Power Supply
(2) Undervoltage Shutdown
(3) Overvoltage Shutdown
(4) Battery Power Connector Disconnect
(5) Shutdown Annunciation
(6) Battery Overtemperature
(7) Battery interlock
(8) Overcurrent
F Charge Cycle Control System

(1) Summary
(2) Base Charge initiation
(3) Charge Mode Control

(4) Base Charging
(5) Temperature Compensated inflection Point
(6) Overcharge initiation
(7) Overcharge Completion, Constant Voltage Region
(8) Comparator Voltage Reference
G Inverter Control
(1) Current Order and Response Control of the PWM
(2) PWM Outputs
(3) PWM Shutdown
(4) Overcurrent Cycling
(5) Regulated Output From PWM
(6) Base Drive Circuit Logic
(7) Turn On
(8) Turn Off
(9) Clamp
(10) Lower Discrete Section
(11) lnverter Circuit Failure
H TR Mode (Constant Voltage) Controls

(1) TR Mode Controls
(2) Voltage Loop Error Signal Control
(3) Current Control
I Low Output Current Operation

(1) Hysteresis Operation
(2) Circuit Description
Page 12
24-31-04 May 25/12
4-254
B. Input Power Circuit
(Figure 2001, Sheet 1 for 4-254-02/-02 MOD1; Figure 2002, Sheet 1 for 4-254-03/-04)
The three phase 400 Hz input power is filtered by the EMI filter section comprising A1 L1-A, B, C,
A1A1 C1-C3 and A1 C1-C3. Full wave rectifier assembly A1CR1 rectifies the input to about 270
V dc. The dc voltage is filtered by A1 L2/L4, low frequency half-bridge capacitors A1 A2 C1 and
C2, A1A2 L3 and high frequency half-bridge capacitors A1A2 C3-C8. Bleeder resistors A1A2 R1
and R2 allow the capacitors C3-C8 to discharge equally when the ac input power is removed.
C. Inverter
The half-bridge inverter transforms the 270 V dc power into a 20 kHz width-modulated quasi-
square wave. The main components in this section are the half-bridge capacitors, the two main
power switching transistors (A2 Q1 and Q2), the main converter transformer (A4 T1) and the
inductor (A1 L3). The saturable turn-on inductor A2 L1 minimizes the power dissipation in A2 Q1
and Q2 during turn-on (each cycle). Snubber rectifiers A2A1 CR2 and CR3, resistors A4 R1 and
R2 and capacitors A4 C1 and C2 protect A2 Q1 and Q2 during turn-off (each cycle).
The base drive transformers (A2A1 T2 and T3), the current sense transformers (A2A1 T1 and
T4), the control circuit power transformer (A1T1) and the output power transformer (A4 T1) all
together provide isolation between the ac input power circuit and the dc output circuit.
D. Power Output Section
Power rectifiers A4A1 CR1 and CR2 rectify the 20 kHz width modulated quasi-square wave from
the half-bridge inverter. The rectified output is a 40 kHz train of width modulated pulses, filtered by
the output filter choke A4L1 and capacitor A5A1 C1. Capacitors A5A1 C2-C3 and snubber
components A4A1 R1, C1, R2 and C2 suppress EMI emissions.
E. Control and Protection Circuits
(See. Section 1. Description)
(1) Control Circuit Power Supply (A3A1)
The control circuit power supply is shown on the power circuit section (Sheet 1) of the
schematic. The ac control power coming from the small 3 phase power transformer T1 (in
the A1 assembly) is rectified by full wave bridge rectifier A1 CR2-CR7, provided to A3A1 at
J1 pins 20/16, and filtered by A3A1 R4 and A3A1 C14. The zener diode A3A1 VR6 is
normally not conducting and is used as a voltage spike clipper for control circuit protection.
A3A1 U9 is a 12 V regulator referenced at 8.2 V dc by A3A1 VR2 to provide a regulated 20
V dc (TP1). Capacitor A3A1 C16 is a high frequency filter.
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4-254
(2) Undervoltage Shutdown-A3A1 (Figure 2001, Sheet 1 for 4-254-02/-02 MOD1; Figure 2002,
Sheet 1 for 4-254-03/-04)
Because power is required to turn off the main power switching transistors on each cycle,
they can be damaged when the supply line voltage is low. However, the following protection
circuit is used:
When the ac input voltage is low, the output of the 20 V supply regulator will also be low.
The voltage on the 20 V supply line (output of U9 Pin 2) is scaled by R52 and R48 and
compared at Pin 3 of U1 with the 2.5 V dc reference voltage on Pin 2. When the 20 V supply
voltage drops to approximately 18 V dc (ac input approximately 94 Vrms), Pin 1 of U1 (TP4)
transmits a low through CR23 and A3A2 R1 to turn A3A2 Q1 on and shutdown the inverter
drive. A3A1 R50 and CR22 cause latching of U1 pin 1 output. The undervoltage shutdown is
not annunciated.
The overvoltage and undervoltage circuits use a 2.5 V dc reference (TP6) provided to U1
pins 2 and 5 by components R75, R76 (select-in-test), R27, R35 and VR5.
(3) Overvoltage Shutdown-A3A1 (Figure 2001, Sheet 1 for 4-254-02/-02 MOD1; Figure 2002,
Sheet 1 for 4-254-03/-04)
The charger shuts down during an ac input overvoltage to prevent damage to the power
circuit due to transient overvoltages generated during switching. A nominal 15 second delay,
after the overvoltage condition clears, allows the voltage to reach normal levels on the half-
bridge capacitors before restarting the converter.
An ac input overvoltage condition (higher than 135 Vrms) causes a higher than normal ac at
the input of the 20 V supply regulator (U9 Pin 1). This voltage is scaled by R49 and R53.
applied to the overvoltage comparator (U1 Pin 6) and compared with the 2.5 V dc reference
(Pin 5). The overvoltage drives U1 Pin 7 low, triggering timer U3. The output of U3 (Pin 5)
goes high, turning on Q8 (TP5) which provides a shutdown signal to A3A2 Q1. The
overvoltage shutdown is not annunciated.
When the ac input returns to an acceptable level, U1 Pin 7 goes high and C20 begins
charging via R54, causing a 15 second delay before a low turns Q8 off to clear the shutdown
condition.
VR7 and R85 prevent a false shutdown during application of input power.
(4) Battery Power Connector Disconnect-A3A1 (Figure 2001, Sheet 1 for 4-254-02/-02 MOD1;
Figure 2002, Sheet 1 for 4-254-03/-04)
If the power connector of the battery is not connected when the ac power is applied to the
battery/Battery Charger system, the sensed voltage at the charger output terminals will be
zero. Conduction through A3A1 J1 Pin 7, CR27 and A3A2 R1 will turn A3A2 Q1 on, causing
shutdown. This occurs whenever the sensed output terminal voltage is lower than
approximately 4 V dc. The shutdown is not annunciated. During shop test, setting the
external power supply below 4 V dc causes shutdown.
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4-254
(5) Shutdown Annunciation-A3A1 (Figure 2001, Sheet 1 for 4-254-02/-02 MOD1; Figure 2002,
Sheet 1 for 4-254-03/-04)
Transistor A3A1 Q2 switches the shutdown annunciation signal. During normal operation,
TP2 is high and A3A1 Q2 is biased on. conducting via A3A1 J1 Pin 12/A6 J1 Pin 9 through
aircraft annunciation control circuits (see overview on page 7/10 herein). When Q2 is biased
off as described in (6) and (7) or when input power fails, the Q2 switch opens, cutting off
current through the aircraft circuit, and shutdown annunciation occurs.
(6) Battery Overtemperature-A3A1 (Figure 2001, Sheet 1 for 4-254-02/-02 MOD1; Figure 2002,
Sheet 1 for 4-254-03/-04)
The thermistor in the battery (1) temperature compensates the charger output, and (2)
indicates if the battery has exceeded a predetermined maximum operating temperature. The
resistance of the thermistor is sensed at A3A1 J1 Pin 3 to Pin 8. In parallel with R18 it
modifies voltage divider (R11, R18 and R19) which is across the output voltage sense
(A3A1 J1 Pin 7 to Pin 15). The scaled, temperature compensated voltage at Pin 13 of U2 is
compared to the scaled voltage at Pin 12 of U2. When the maximum battery operating
temperature is reached, the level at Pin 13 of U2 decreases enough to cut U2 off, snapping
the U2 output high.
A3A1 CR14/R24 conduct through U2 pin 14, biasing Q3 on (TP2 goes low). Then
conduction through A3A1 CR7 turns A3A2 Q1 on, sending a shutdown signal (high) to A3A2
U1 pin 10. The low at TP2 also biases switch A3A1 Q2 off, causing annunciation described
in (5).
R39 and CR16 provide approximately 10°F hysteresis for the battery overtemperature
shutdown function. After the temperature falls below this hysteresis range, the shutdown will
clear.
(7) Battery lnterlock-A3A1 (Figure 2001, Sheet 1 for 4-254-02/-02 MOD1; Figure 2002, Sheet 1
for 4-254-03/-04)
The battery interlock sense path is A3A1J1 Pin 6 (circuit ground), A6 J1 Pin 3, through the
battery cable, the battery interlock jumper, back to A6 J1 Pin 1, A3A1 J1 Pin 13 to the
junction of R28 and R30. If the battery is not connected to the sense and control cable, the
above interlock circuit will be open. The junction of R28 and R30 will rise to approximately
2 V dc, biasing Q3 on (TP2). This causes shutdown and annunciation as described in (6).
When the interlock circuit is restored, the shutdown will clear.
(8) Overcurrent
Output current regulation normally limits the output current to 38 A in the charge mode and
64 A in the TR mode. However, if the current in the charge cycle exceeds 38 A due to failure
of current regulation control circuitry, excess battery temperature will cause the battery
overtemperature protection circuit (see E.(6)) to operate. If the failure is in the TR mode, an
overcurrent signal will be generated by A3A2U3 when the output current reaches 70 A.
The 70 A overcurrent condition or an unbalance of either the A2 inverter circuits or the A3A2
inverter drive/drive logic circuitry will cause a cyclic turn off and turn on (soft start) of the
inverter circuit. Overcurrent cycling is described in Section G.(4).
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F. Charge Cycle Control System (Figure 2001 for 4-254-02/-02 MOD1; Figure 2002 for
4-254-03/-04)
(1) Summary
The charge cycle control circuits in A3A1 include the following:
(a) Base charge initiator (U2 Pins 5, 6 and 7).
(b) Battery overtemperature protection comparator (U2 Pins 12, 13 and 14), described
earlier.
(c) Overcharge initiation comparator (U2 Pins 1, 2 and 3).
(d) For the 4-254-02: Constant voltage loop error amplifier (U2 Pins 8, 9 and 10) (also
used in the TR mode).
(e) Oscillator (U3 Pin 9 output) with oscillator capacitor (C23).
(f) Seven stage frequency divider (U4).
(g) Three NAND gates (U5).
(h) Two 4 bit up/down counters (U6 and U7).
(i) Two OR gates (U8).

(j) 2.53 V dc reference voltage circuit (R37, VR4, R38 and R40), reference for (a), (c) and
(d), above.
(2) Base Charge Initiation-A3A1 (Figure 2001, Sheet 1 for 4-254-02/-02 MOD1; Figure 2002,
Sheet 1 for 4-254-03/-04)
The base charge region of the charge cycle (see Figure 3) is initiated under any of the
following conditions:
• Battery voltage (sensed at A3A1J1 Pin 7)  23 V dc. Voltage is scaled by A3A1 R26 and
R21 and compared at U2 Pin 5 with a 2.53 V dc reference voltage on U2 Pin 6.
• Set to Charge Mode after TR mode  500 ms. A3A1 C7 is charged via R10 and R12
while in TR mode. When A3A1 J1 Pin 10 is grounded again, C7 discharges through
R26. If C7 was charged  500 ms, the discharge current will drive U2 pin 5 low enough
to change the state of the comparator and initiate a new charge cycle.
• Initial application of input power or interruption 500 ms. A3A1 C26 is discharged via
R73 while the power is interrupted. If C26 is discharged  500 ms, the charge current
(when power is reapplied) via CR24 and R70 will bias Q7. Q7 conduction through R23
and R26 will apply a low to U2 pin 5, initiating a new charge cycle.
When one of the above occurs, U2 pin 7 goes low, and is latched by R44 and CR19 to hold
the circuit in base charge until outputs of the counters (U6 and U7) are present to control the
base charge region, as described later.
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4-254
Charge Control Circuits Block Diagram (4-254-02)
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4-254
Charge Control Circuits Block Diagram (4-254-03/-04)
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(3) Charge Mode Control
In the Charge Mode, A3A1 J1 Pin 10 is grounded by an aircraft system switch (Mode
Selector Switch) to circuit/control common (negative output terminal) biasing Q10 off. Highs
from counters U6 and U7 via OR gate U8 and CR5/6 keep Q11 turned on. When Q11 is
conducting (which will be until overcharge termination) the analog voltage loop error signal
is prevented from effecting the current control as follows: voltage divider R22 and R25 at the
constant voltage loop error amplifier (U2 pin 9, 10 and 8) is modified. This applies a low to
U2 Pin 9 which is compared to the 2.53 V dc reference on U2 Pin 10. The subsequent high
from U2 Pin 8 (voltage loop error signal) cuts A3A2 CR37 off. When it is high, the analog
voltage loop error signal has no effect on current control at A3A2 U1.
The Charge Mode control also causes A3A2 Q5 and Q6 to conduct, shunting R85.
Therefore, the remaining (R6/R84) portion of the current order divider sets a current order at
A3A2 U1 Pin 2 for 38 A constant current to charge the battery.
The current order function and current error amplifier is described in G. herein.
(4) Base Charging-A3A1 (Figure 2001, Sheet 1 for 4-254-02/-02 MOD1; Figure 2002, Sheet 1
for 4-254-03/-04)
During the base charge (A3A1 U2 Pin 7 low) Q6 conducts, providing:
• Current source to charge oscillator capacitor C23, via R65.
• High to NAND gate U5 Pin 5.

• High to NAND gate U5 Pin 2.
• High to NAND gate U5 Pin 1, via CR26/R79.
• Turn on for Q11 via CR26.
The oscillator A3A1 U3 pulse repetition rate is controlled by C23. With Q6 conducting, the
sawtooth on C23 and the output of U3 Pin 9 (TP9) will have a pulse repetition of about 188
ms. U3 Pin 13 causes the discharge of C23 via R66 at each pulse.
The oscillator output (A3A1 U3 pin 9) is applied to Pin 1 of frequency divider U4. The output
of U4 Pin 3 is a 24 second period square wave, applied to U5 Pin 8 and 11. With a high on
U5 Pins 1 and 2, the square wave passes the NAND gate from Pin 9, which is connected to
the upcount input (Pin 5) of U7. The high on U5 Pin 5 causes a low to U5 Pins 6 and 13,
preventing the signal from U4 from passing that NAND gate (U5 output Pin 10) to the
downcount input of U7. Thus, U6 and U7 are counting up during the base charge time.
During normal operation A3A1 C1 is statically charged. When input power is interrupted, C1
begins discharging via R71 and if power is reapplied after > 7 seconds, C1 charging via CR1
and R68 causes a high on Pin 14 of both U6 and U7, resetting the counters. This reset
circuit allows the counter to hold the count during short power interruptions, but assures
charge cycle re-initiation after longer power interruptions.
When neither the base charge or overcharge functions are operating, A3A1 CR28 and
CR29 and R42 allow Pin 2 of frequency divider U4 to go high, resetting A3A1 U4. Resetting
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4-254
U4 assures that the initial count in U7 occurs consistently after 24 seconds from the initiation
of base charge.
(5) Temperature Compensated Inflection Point
A3A1 U2 Pin 1, 2 and 3 is the overcharge initiation comparator. The output voltage is
sensed at A3A1 J1 Pins 7 to 15 and scaled by R19, R18/battery thermistor (A3A1 J1 pins 8
and 3), and R11. The scaled voltage across R19 is applied to Pin 2 of U2 and compared to
the 2.53 V dc reference at Pin 3 of U2. When the output voltage sensed at A3A1 J1 reaches
the temperature compensated Inflection point (31.3 V dc at 77 °F; battery fully base
charged), U2 Pin 2 becomes higher than the reference and Pin 1 of U2 goes low, initiating
the overcharge.
NOTE: The temperature compensation is provided by the battery thermistor in parallel with
R18 (A3A1 J1 Pins 8 and 3). At 77 °F battery temperature the thermistor resistance
is 2.25 k . As temperature increases, the parallel resistance decreases, and the
voltage on R19 (U2 Pin 2) increases.
(6) Overcharge Initiation (A3A1)
When overcharge is initiated as above, the low from Pin 1 of U2 is applied to pin 6 of the
base charge initiator (U2 Pin 6/5/7) to shut it off and to turn Q5 on.
With the base charge initiator shut off, the high U2 pin 7 output turns Q6 off. However, Q5 is
now turned on, providing a higher current source and charge rate to C23 (via R66 instead of
R65).
NOTE: In the 10% overcharge application a jumper is connected in aircraft wiring (A6 J1
Pins 5 and 6) which effectively places A3A1J1 Pin 1 (and the base of Q4) at circuit
ground.
The sawtooth repetition rate at C23 and the output of oscillator U3 Pin 9 (TP9) is nominally
9.9 ms for 5% overcharge (or 19.8 ms to 23.8 ms * for 10%/12% overcharge). The logic
using U5 causes the up/down counters U6 and U7 to count down.
• The 4-254353-02 and later configurations of A3A1 provide a nominal 23.8 ms rate. This
configuration is effective in all units S/N 232 and above, and can be installed in earlier
units.
(7) Overcharge Completion, Constant Voltage Region (A3A1)
When the counter completes its countdown to all lows, the common cathode connection of
CR5 and CR6 goes low and Q11 turns off. With Q11 cut off, the voltage monitor input to the
constant voltage loop error amplifier (U2 Pin 9) is allowed to be controlled by the output
voltage, sensed at A3A1J1 Pins 7 and 15.
The sensed output voltage is scaled by R22 and R25, causing an analog level on Pin 9
which is compared with the 2.5 V dc reference on Pin 10. The analog output level from the
constant voltage loop error amplifier (U2 Pin 8) is the current level required (38 A maximum)
to maintain 27.75 V dc across the aircraft load and/or battery (TB1 + and - terminals).
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4-254
After Q11 turns off as above, the Battery Charger operates in the constant voltage region of
the charge cycle. The constant 27.75 V dc maintains the charge on the battery in the aircraft
system.
The stability network for the constant voltage loop error amplifier is R16, R45 and C13.
Diodes CR11 and CR12 prevent the U6 and U7 counters from underflowing at the end of the
overcharge.
NOTE: See H. herein for more detailed description of constant voltage functions, and G. for
description of PWM/current control functions.
(8) Comparator Voltage Reference
The 2.53 V dc from the R37, VR4, R38 and R40 network is the reference for the base
charge initiation circuit (Pins 6, 5 and 7 of U2). the overcharge initiation circuit (Pins 3, 2 and
1 of U2), and the constant voltage loop error amplifier (Pins 10, 9 and 8 of U2). Select-in-test
resistor R38 calibrates the reference voltage.
G. Inverter Control
(A3A2; Figure 2001, Sheet 1 for 4-254-02/-02 MOD1; Figure 2002, Sheet 1 for 4-254-03/-04)
The PWM (A3A2 U1) is the heart of the control system for the Battery Charger. The PWM (Pulse
Width Modulator) outputs control the power switcher drive signals.
(1) Current Order and Response Control of the PWM (A3A2)

The current error amplifier is A3A2 U1 pins 2 (current order) and pin 1 (current response
from A3A1 J1 pin 11 via Q17 and Q18). The current error amplifier output to the PWM in U1
is seen at pin 9. It is there that the soft-start components have their effect.
The current response sensed by A2A1T1 and T4 is applied at A3A2 J1 Pins 11 and 1. The
peak value is nearly proportional to the converter output current. A3A2 CR9, Q17 and Q18
couple the current signal across C3 and R22 to U1 Pin 1. In the 4-254-02, the signal goes
through the stability circuit R15, R16, R17 and C2.
The current order set points are established by the current order divider which includes R6,
R84 and R85. The current order voltage level is applied to Pin 2 of U1. A higher voltage
represents a higher current order set point.
In the TR mode, Q5 and Q6 are nonconducting. With R85 not shunted by Q6; the current
order divider includes R6, R84 and R85 and the maximum current order is about 64 A. See
H. herein for more description of TR Mode functions and the method of voltage control in the
TR Mode.
In the charge mode, Q5 and Q6 both conduct, shunting R85, and modifying the current
order voltage divider, resulting in a lower maximum current order signal (representing
approximately 38 A). While in the charge region of the charge cycle, the current order divider
includes R6 and R84.
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4-254
A lower current feedback signal at U2 pin 1 compared with the current order signal at pin 2
would cause the current error amplifier output (seen at pin 9) to go higher. A higher current
error signal level would drive the PWM duty cycles wider (see Figure 7) to maintain the
charger output current at a constant 38 A.
The current error amplifier (U2 pin 9) output level is represented by the horizontal dashed
line on the oscillator waveform on Figure 7.
In the 4-254-02 constant voltage region, the voltage loop error signal has analog control of
A3A2 U1 pin 2 (current order input) level (within maximum range). In the Charge Cycle, the
voltage loop error signal is high so the U1 pin 2 level is set at the maximum level allowed by
the current order voltage divider.
In the 4-254-03/-04, the voltage loop error signal interfaces directly to pin 9 of U1
(SG1524B) via an additional stability network, R95, CR41, R96, and C40, and coupling
diode CR37, rather than via the current order input. Therefore, in the constant voltage region
the voltage loop has direct analog control of the current error amp output (to the maximum
current level allowed by the current order voltage divider). In the charge mode, the voltage
loop is high so the current error amp has analog control.
Control of the PWM current control by the voltage loop error amplifier will be explained in H.
The following is a summary of control conditions:
PWM Duty Cycle controlled via current error amplifier (U2 pins 2/1) during:
• 4-254-02 or 4-254-031-04 Charge Mode Charge Cycle

4-254-02 TR Mode or Charge Mode constant voltage region
• PWM duty cycle directly controlled by the voltage loop error signal:
• 4-254-03/-04 TR Mode or Charge Mode constant voltage region
(2) PWM outputs
The output of the PWM are two 20 kHz pulses; the duration controlled by the Current error
output seen at A3A2 U1 pin 9. Description of this was given in (1).
Components C4, R23 and R24 set the fixed operating frequency of the oscillator to 40 kHz;
select-in-test resistor R24 trims the operating frequency.
NOTE: See Figure 7 for the general relationship of PWM output signals and inverter control
signal pulses.
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4-254
25 μS
A3A2U1 OSCILLATOR FREQUENCY CONTROLLED

AT PIN 7 (C4) BY C4 AND R23, TRIMMED
5 μS BY R24 CAL RESISTOR
A3A2U1 REAL TIME LIMITS MAX DUTY

PULSE AT PIN 3 CYCLE OF ON DRIVE
A3A2U1 PWM OUTPUT A2Q1 ON DRIVE

AT PIN 11
A2Q2 ON DRIVE
A3A2U1 PWM OUTPUT
AT PIN 14
A3A2U5 OUTPUT A2Q1 OFF DRIVE

END IF
AT PIN 4, TP14 (UNRESET ~
~ 6 USEC)
NOT RESET
(NO RESET IN 4-254-03)
A3A2U5 OUTPUT
AT PIN 12, TP15
A2Q2 OFF DRIVE
(NO RESET IN 4-254-03)
RESET OFF DRIVE

A3A2U5 RESET INPUT AT END OF A2Q1/2
AT PIN 3/11 STORAGE TIME
A2Q1 CLAMP
A3A2U7 CLAMP PULSE
AT PIN 7
A3A2U8 CLAMP PULSE

AT PIN 7 A2Q2 CLAMP
4 254 V0021 EX FIG 7
Figure 7
Inverter Control Waveform Relationships
Page 23
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4-254
Each PWM output pulse energizes the drive circuit for one power switcher transistor. It also
energizes the monostable multivibrator (U5) to provide, after a delay determined by the U5
circuit, negative pulses to the switcher off-drive circuits.
To prevent a malfunction due to one drive transistor turning on before the other completely
turns off, a controlled amount of dead time is required between the positive pulse outputs of
U1 (Pins 11 and 14). The Q3 and Q4 circuit on Pin 3 of U1 controls the deadtime. Pin 3 is
normally low; Q4 off, and Q3 on (approximately 4.4 V on R25). When the otherwise narrow
positive pulse from Pin 3 is applied at the start of dead time, approximately +9.4 V is felt on
R25, cutting Q3 off and turning Q4 on. The conduction of Q4 holds Pin 3 high until the
voltage on R25 drops (C5/R25) sufficiently to turn Q3 on, and Q4 off, terminating the dead
time pulse.
(3) PWM Shutdown (A3A2)
The PWM can be shutdown by all of the protection systems described in Control and
Protection Circuits, sub-paragraphs E.(1) through E.(8). under this section (Description and
Operation). The shutdown signals from the A3A1 control and protection circuits are lows,
through R1 to turn Q1 on, applying a high to the PWM shutdown input, U1 Pin 10.
Either an unbalance (due to component/failure) of the A2 inverter circuit or A3A2 inverter

drive/drive logic circuit, or an output current of 70 A (due to control circuit failure) normally
causes an intermittent “cycling” shutdown only. The overcurrent shutdown signal (a negative
pulse) from U3 Pin 4 is applied to Q1 through R10.
(4) Overcurrent Cycling (A3A2)

Under normal Battery Charger operation, the output current is limited to 38 A in the charge
mode and 64 A in the TR mode by regulation/control circuits.
However, if failure of the regulation/control circuits allows output current of 70 A or more, or

if an unbalance of the A2 inverter circuit or its drive circuitry in A3A2 occurs, an overcurrent
is detected by current sense transformers A2A1T1 and T4. The current is rectified by
A2A1CR1 and CR4 and sensed at A3A2J1 Pins 11 and 1.
The current limit is set by select-in-test resistor R28. The high input to the current limit
comparator (U2 Pin 4) is compared to the approximately 3.17 V dc on Pin 3. The low from
Pin 1 is applied to the A input (Pin 1) of monostable multivibrator U3.
The output of U3 (Pin 4) is a negative pulse of approximately 60 ms. It is applied to the base
drive logic (U6) for immediate logic shutdown, and determines the length of the shutdown.
The pulse is also applied, via R10, to turn Q1 on.
When Q1 conducts, it not only activates the PWM shutdown (U1 Pin 10), but also it sets the
“soft start’ circuit (Q2, C1, R14 and CR8 in the 4-254-02), applying a low (shutdown) to U1
Pin 9.* When the shutdown pulse from U3 Pin 4 clears, Q1 and Q2 are turned off and the
soft start components slowly allow the pulse width of the pulse from the PWM to increase.
The soft start action completes in about 25 ms time (10 ms for the 4-254-03/-04).
• On the 4-254-03\-04, the soft start operates in the same manner with the exception that
the stability network components (R16 and C2) also perform the soft start function; com-
ponents C1, R14, and CR8 are not used.
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The overcurrent shutdown/soft start cycle repeats as long as the overcurrent condition
continues. The total period of each cycle is approximately 85 milliseconds.
(5) Regulated Output From PWM (A3A2)
In addition to PWM functions, U1 provides a regulated 5 V dc output at Pin 16. External

transistor A3A1Q1, with A3A1R17, boosts the current capability of the regulated 5V output.
This supply powers the logic circuitry in the converter basedrive circuit described below and
is a reference source for the current order circuit previously described in F.(3), F.(6) and
G.(1).
(6) Base Drive Circuit Logic (A3A2)
U7 and U8 interface between the low power logic section and the discrete section of the
base drive circuit. The outputs of U7 and U8 drive the on drivers Q16 and Q15, the off
drivers Q14 and Q10, and clamp driven Q20 and Q19.
Diodes CR20 and CR29-32 are limiters for the logic circuits. Signals coupled through the
input capacitors are limited to < 5 V by VR3 (2.4V) in series with the diodes.
The sequence of base drive logic is turn on, turn off and clamp; See Figure 7.
The PWM outputs are passed by U6, unless U6 is inhibited by current limit from U3, to the
schmidt trigger inputs of U5 (described below) and via U4 to U7 and U8.
(7) Turn On (A3A2)

A high from U8 Pin 2 initiates the turn on of Q16. Current through Q16, A2A1 T2 (A3A2 J1
Pin 5 and 8) and C22 to the 20 V dc supply line initiates the turn on of main power switching
transistor A2Q1. During turn on, Q11 is off and Q12 and Q13 are conducting.
Q13, driven by Q12, is a current source for C22. C22 charges in proportion to the base-
emitter voltage on A2Q1. The clamp (Q11) is turned off at the same time Q16 is turned on.
(8) Turn Off (A3A2)
The turn off signal is controlled by U5. U5 is a dual monostable multivibrator (54LS221).
When a positive PWM pulse is applied to U5 Pin 1, U5 has a fixed delay before passing a
negative pulse which is then inverted by the driver, U7, to turn the turn-off drive transistor
Q14 on.
Q14 conducts through the turn off winding of A2T2 via A3A2 J1 Pins 12 and 3, and R90.
Q14 must conduct long enough to remove the stored charge in the power switch circuit. The
conduction time of Q14 is controlled by the duration of the turn off output of U5 pin 3. This
time is fixed in the 4-254-03/-04.
In the 4-254-02, the U5 turn-off is reset (see Figure 7). When the main power switching
transistor collector current decreases to about 25 mA, the turn-off is detected at the current
sense transformer (A2A1 T1). The low at U6 Pin 6 causes a (low) clear pulse to be applied
to U5 Pin 3, terminating the turn-off output, cutting Q14 conduction off.
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(9) Clamp (A3A2)
When the turn-off output from U5 is terminated, a clamp signal passes the logic circuits.
Clamp driver Q20 is turned on, driving Q11 on and Q12 off. Q11 connects a section of the
primary of A2T2 (A3A2J1 Pins 5 and 8) across C22 with the polarity required to reset T2 for
the next on pulse.
(10) Lower Discrete Section (A3A2)
The lower discrete section of the base drive circuit functions in the same manner as
described above in (7), (8), and (9) for A2Q1 drive. The lower section drives A2Q2.
(11) Inverter Circuit Failure (A3A2)
Failure of a power circuit or a drive circuit component will usually cause an unbalance
condition within the power circuit. This unbalance will cause in an overcurrent condition
through either of the main power switching transistors, sensed by the current sensing
transformers. The charger will begin the overcurrent cycling in the cyclic turn off and soft
start turn on mode of operation described in E.(4), limiting the current in a controlled
manner. In most cases, further component failures will be prevented.
H. TR Mode (Constant Voltage) Controls
(Figure 2001 for 4-254-02/-02 MOD1; Figure 2002 for 4-254-03/-04)
(1) TR Mode Controls

In the TR Mode, A3A2 Q5 base voltage is high, cutting Q5 and Q6 off, so R85 is not
shunted. The current order to A3A2 U1 pin 2 is (as high as) 60A.
Also, in the TR Mode A3A1J1 pin 10 is high, A3A1 Q10 is on, and Q11 is biased off. In this
state, the A3A1 R25/R22 voltage divider (sensed charger output voltage) is allowed to
control constant voltage regulator A3A1U2 pins 9/10/8 in an analog manner.
A lower battery/load voltage at A3A1 J1 pin 7 would cause the U2 pin 9 voltage (R25122
junction) to be lower. This compared with U2 pin 10 reference would drive U2 pin 8 (voltage
loop error signal) to A3A2 CR37 in the positive direction.
(2) Voltage Loop Error Signal Control
In the 4-254-02, the constant voltage loop error amplifier (A3A1 U2 Pin 8) sends the current
order signal to the PWM that will direct enough current, to the maximum determined by
mode, to maintain 27.75 V dc across the output loads. A higher voltage loop error signal via
A3A2 CR37 would cause an increased current order to U1 pin 2 (input to current error
amplifier). This is compared with the current response signal at pin 1 (from Q17/18). As pin 2
goes positive, the current error amplifier output signal (seen at pin 9) to the PWM goes
higher.
In the 4-254-03/-04, the constant voltage loop error amplifier output signal does not operate
through the current order signal. The analog voltage loop error signal output from A3A1 U2
pin 8 is applied via A3A2 CR37 directly to the current error amplifier output (seen at A3A2
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4-254
U1 pin 9). A higher A3A1 U2 pin 8 voltage would increase the current error amplifier output
voltage level.
(3) Current Control
If the current error amplifier output signal (seen at A3A2 U1 pin 9) goes higher, it causes the
PWM duty cycle pulses to widen for more charger output current. (The horizontal dashed
line on the oscillator waveform of Figure 7 represents the current error amplifier output
voltage level.) Increased current output will pull the voltage across the load up.
I. Low Output Current Operation (A3A2) (4-254-03/-04 only)
(1) Hysteresis Operation
When operating at low output currents (< 3 A) in the constant voltage region, the
4-254-031-04 configuration functions in a cyclic off/on manner. The hysteresis type mode of
operation produces a sawtooth voltage waveform of approximately 100 mVp-p
superimposed upon the 27.75 V dc charger output.
(2) Circuit Description
A3A2 components R93, R32, R94 and comparator U2 pins 8/9/6 produce this hysteresis.
Capacitors C8 and C39 are signal filter caps. The output (U2 pin 6) is sent to the shutdown/
soft start circuit Q2 via CR40. R36 is a pull-up resistor. The function is as follows:
In the constant voltage operation as a small charger output current is applied to the battery,
the battery voltage increases. This causes the voltage loop error signal to decrease. The
lower voltage loop signal not only causes U1-9 to go lower (reducing PWM duty cycle) but
by a low at U2 pin 9 causes U2 pin 6 voltage to increase (A feedback action pulls U2 pin 8
up, causing a sharper pin 6 increase.) The high at pin 6 turns Q2 on, discharging C2 and
pulling U1 pin 9 down, which cuts off charger output current completely.
The battery voltage decay (with charge current cut off) will cause the voltage loop error
signal to increase. At a certain point U2 pin 9 will increase enough to set U2 pin 6 low. Then
Q2 will be cut off, and the soft start will begin; C2 will charge via R16, U1 pin 9 voltage will
increase, PWM duty cycle increase, and charge current will begin.
The current output will bring the battery voltage up quickly to the level that will cause the
cycle to begin again. The charge current will be cut off so quickly and sharply it will just be a
pulse.
Page 27
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4-254
(3) Leading Particulars
Table 1
Leading Particulars Specification
Input Power 400 Hz

105 to 122 Vrms
3 phase
7.5 A/phase at full load
Output Current/Voltage:
Charge Mode, Constant Current Region 38 ± 2 A, 20 to 36 V dc
Charge Mode, Constant Voltage Region 0-38 ± 2 A, 27.75 ± 0.3 V dc
TR Mode: 0-64 ± 1 A, 27.25 - 28.05 V dc
Efficiency 82% or greater
Overcharge (Normal) Overcharge time equals 5% of base charge time
Overcharge (High Capacity Application) Overcharge time equals  10% of base charge time
(12% for charger Serial Number 232 and above)
Length 14.6 inch (37.1 cm) (includes handles)
Width 7.6 inches (19.3 cm)
Height 7.6 inches (19.3 cm)
weight 21 pounds (9.5 kg)

External Connections;
Power Output (TB1) Negative (–) Terminal (5/16 inch) and
Input Power/Sense/Control (A6J1) Positive (+) Terminal (3/8 inch)
12-pin male connector
Cooling:
Convection 136.4 °F (58 °C) ambient air (to 50 A)
Forced Air 75 pounds (34 kg)/hour (to 60 A)
Cooling Features Externally finned heat sinks, both sides; convection

orifices
Page 28
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4-254
NOTE: ELDEC approved technical data and its referenced test equipment can be used as an
alternative to the Testing and Fault Isolation procedures in this section. Only the latest released
revision of this data shall be used.
1. Testing
A. Test Equipment
Table 1001 gives the equipment necessary to test the Battery Charger. Equivalent replacements
can be used for the items given in this table, unless noted. Figure 1001 shows a schematic
diagram for the variable resistive load. Table 1002 gives the parts necessary to build a variable
resistive load. Figure 1002 shows the Pre-Performance test equipment setup to do the Reverse
Current test. Figure 1003 shows the Battery Charger Test Circuit to do the Performance Tests.
Table 1001 (Sheet 1 of 2)

Equipment Necessary for Testing
ITEM USAGE/RANGE/PRECISION RECOMMENDED MODEL
Source, 115 V ac input 115 ± 1.0 V ac, Various

400 Hz, 3-phase, 20 A
Variable Transformer 0 - 140 V ac, 20 A Superior Electric (V58474) F136

(3 necessary)
Megohmmeter 500 V dc ± 2.5% QuadTech (V0PK96) 1863
Current Shunt 100 A, 100 mV or greater, EMPRO (V03030) HA100-100

± 0.25%
Oscilloscope 100 MHz, 3% Tektronix (V80009) 465B
Decade Resistor Box 0.02 - 0.1% QuadTech (V0PK96) 1433
Power Supply, External 40 V dc, 50 A Agilent Technologies (V2D895)

HP6269B
Digital Multimeter (2 necessary) 0 - 200 V ac, 0 - 200 V dc, Fluke (V0HYG7) 8050A or
0 - 200 mA (max.) 8840A
Current Probe 3% Tektronix (V80009) P6021

or
Volt-Amp-Wattmeter 0.5% (current) Electrical Instrument Services
(VAW Meter) 0.75% (voltage) (V32590) VAW Meter
Stopwatch 0.1 second resolution Various
Connector J1 Battery Charger connection Amphenol (V02660)

BACC45FT14-12S
Switch (4 necessary) 1 A, SPST Various
Page 1001
24-31-04 Nov 14/14
4-254

Equipment Necessary for Testing
ITEM USAGE/RANGE/PRECISION RECOMMENDED MODEL
Reverse Voltage Protection > 25 A 1N1184

Diode and Isolation Diode
(2 necessary)
5 V dc Power Supply 5 V dc, 1 A Kikusui (V61993) PA32-2A
Light Emitting Diode (LED) 5 V dc Quality Technologies Corp

(V0MS63) MV5025A
Circuit Breaker 7.5 A, 140 V ac, 400 Hz, Various

3-phase
Resistor 1 M , 5%, 1/4 W Various
Resistor 560  , 1/4 W RLR07C5600GS

or
RLR07C5600GR
Capacitor1 10,000 µF, 75 V dc Various
Variable Resistive Load2 See footnote3 3-228 ELDEC (V08748)

See Figure 1001 for an

equivalent circuit schematic
1. The 10,000 µF electrolytic capacitor must be temporarily disconnected from the Variable
Resistive Load to do the Overvoltage Protection Tests, step (4)(a)3. When you set up the test cir-
cuit shown in Figure 1003, make sure you can easily disconnect and reconnect this capacitor.
2. The Variable Resistive Load is designed to test the 4-254 with the procedures in this manual.
3. The Variable Resistive Load must have the capability to conduct a load current that can change
from 8 A at 10 V dc to 64 A at 28 V dc. Maximum voltage for this Variable Resistive Load is 39 V
dc; maximum power is 1800 W. The Variable Resistive Load must be cooled, have the correct
wiring to conduct the current, and have a wide range of resistance steps. A schematic diagram
for a Variable Resistive Load is shown in Figure 1001, and the related parts list is given in
Table 1002. The current range of the Variable Resistive Load that is shown is 0 – 200 A.
A solid-state load can be used as an alternative to the Variable Resistive Load. If a solid state
load is used, it must operate in the Constant Resistance mode. Some solid state loads can make
the Battery Charger operation unstable. If the Battery Charger operation is not stable, stop
operation, and use a resistive load instead.
Page 1002
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4-254
POS BUS BAR
2Ω 2Ω R25
J1 R1 R13
S1 S13 20Ω
R2 2Ω R14 2Ω
S2 S14
R3 2Ω R15 2Ω
K1 S3 S15
R4 2Ω R16 2Ω R26
S4 S16 50Ω
R5 2Ω R17 2Ω
S5 S17
BUS BAR
R6 2Ω R18 2Ω
S6 S18
R7 2Ω R19 25Ω
S7 S19
BUS BAR
R8 2Ω R20 25Ω
S8 S20
R9 2Ω R21 10Ω
S9 S21
R10 2Ω R22 10Ω
S10 S22
R11 2Ω R23 10Ω
S11 S23
S25
R12 2Ω R24 10Ω

NEG S12 S24
BUS BAR
J2 T1 B1
BR1
C1
500μF AC AC BLOWER
50V
120 VAC
60 HZ S26
WHEN ASSEMBLING, USE DMM TO SET RESISTORS TO VALUES SHOWN.
MANUFACTURE BUS BAR FROM 1/0 WELDING CABLE FOR CURRENT

CAPABILITY. DASHED LINE INDICATES THE EQUIVALENT DC POWER
SUPPLY (SEE TABLE 102).
8-930_03T0011B
Figure 1001
Variable Resistive Load
Page 1003
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4-254
Table 1002
Variable Resistive Load Parts
Designator Description Suggested Part No. Supplier
R1-R18 Resistor, 2.2  , 700W PFE5K2R20 Ohmite (V44655)
R19, R20 Resistor, 25  , 200W minimum PFR5K25R0 Ohmite (V44655)
R21-R24 Resistor, 11  , 300W minimum PFR5K11R0 Ohmite (V44655)
R25 Resistor, 20  , 200W minimum PFR5K20R0 Ohmite (V44655)
R26 Rheostat (Resistor), 50  , 150W RLS60R Ohmite (V44655)
S1-S25 Toggle Switch (SPST), 20 A dc 8500K9 Eaton (V15605)
S26 Toggle Switch (DPDT) 8501K9 Eaton (V15605)
K1 Relay, 24 V dc, 200 A 586-905 Stancor (V0FRE0)
J1 Power Connector, 250 A, Red PP250GR Superior (V58474)
J2 Power Connector, 250 A, Black PP250GB Superior (V58474)
B1 Blower, 120 V ac, 60 Hz (also NEVB-360MOD1 ElectroRack (V26073)

available for 220 V ac, 50 Hz)
BR12 Bridge Rectifier, 6 A, 400 V 925-0278 or Allied (V3F511)

equivalent
C12 Capacitor, 500 µF, 50 V Electrolytic 852-9038 or Allied (V3F511)

equivalent
T12 Transformer P8615 or Stancor (V0FRE0)

equivalent
--- Power Supply3, 24 V dc, 3.6 A (input SLS-24-036T or Sola/Hevi-Duty

ac-power adjustment) equivalent Electric (V7L704)
--- Dial Plate (for R26) 5001 Ohmite (V44655)
--- Knob (for R26) 5106 Ohmite (V44655)
--- 1/0 Welding Cable See Note4
1. MOD indicates that it is necessary to give the vendor the input ac power specifications for blower.
2. These power supply components are for older variable resistive loads. Use the recommended
power supply (SLS-24-036T or equivalent) to build a new variable resistive load.
3. This is a power supply that can be quickly changed to meet different input ac power
specifications.
4. Commonly available from industrial suppliers.
Page 1004
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B. Pre-Performance Tests
CAUTION: MAKE SURE THE TEST VOLTAGE IS APPLIED TO THE CORRECT BATTERY
CHARGER OUTPUT TERMINALS (TB1). BATTERY CHARGER CIRCUITS COULD BE
DAMAGED IF THE TEST VOLTAGE IS NOT APPLIED TO THE CORRECT OUTPUT
TERMINALS.
(1) Insulation Resistance
Each row in Table 1003 references a test step [(a), (b), and (c)] in the insulation resistance
test. Refer to the instructions in each test step and connect a megohmmeter or equivalent to
the Battery Charger. Apply a 200 V dc test voltage for 2 minutes at each test step. Make
sure the insulation resistance is > 10 M at each test step.
Table 1003
Insulation Resistance Test Steps
APPLY 200 V DC TEST VOLTAGE FOR 2 MINUTES
FROM TO
(a) Inputs (A6J1 pins 4, 7, and 10) jumpered Both Output Terminals and Inputs (A6J1 pins 1, 3,
together 5, 6, 8, 9, 11, and 12) jumpered together
(b) Inputs (A6J1 pins 4, 7, and 10) jumpered Chassis and Input (A6J1 pin 2) jumpered together
together
(c) Both Output Terminals and Inputs (A6J1 pins 1, Chassis and Input (A6J1 pin 2) jumpered together
3, 5, 6, 8, 9, 11, and 12) jumpered together
(2) Chassis Ground Continuity
With the digital multimeter set to measure resistance, measure the continuity from A6J1 pin
2 to the chassis mounting strap (see IPL Figure 1, item 25). The multimeter shall indicate a
resistance of < 1  .
If the resistance is > 1  , do the fault isolation procedures that follow and do this Chassis
Ground Continuity test again:
(a) Make sure the fasteners that attach the chassis are torqued to the specifications.
(Refer to Fastener Torque Values in FITS AND CLEARANCES.)
(b) Partially disassemble the Battery Charger to see the connection between A6J1 pin 2
and the chassis. (Refer to DISASSEMBLY.) Make sure the screw that makes this
connection is tight.
(c) Make sure there is no corrosion at or near A6J1 pin 2, the chassis connections, and
the chassis fasteners.
Page 1005
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(3) Reverse Current
Do this reverse current test before 115 V ac input source power is applied to the Battery
Charger. This test makes sure the output circuit of the Battery Charger is not shorted before
the Performance Tests are done.
(a) Set up the test equipment as shown in Figure 1002.
(b) Set up the external power supply to current limit at 1 A. Set the output voltage from the
external power supply to 0 V dc.
Figure 1002
Reverse Current Test Setup
(c) Connect the external power supply to the Battery Charger Output Terminals (positive
to positive and negative to negative). Set the digital multimeter on the 200 mA range.
(d) Do not apply 115 V ac input source power to the Battery Charger. Set the external
power supply to ON. Increase the external power supply voltage to 32 V dc. Make sure
that external power-supply current is  32 mA and  18 mA. (For Battery Chargers
that are P/N 4-254-02 MOD1 and P/N 4-254-04, make sure the external power-supply
current is  50 mA.)
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C. Performance Tests
CAUTION: MAKE SURE THE CONNECTIONS AT THE OUTPUT TERMINALS (TB1) AND THE
VARIABLE RESISTIVE LOAD ARE TIGHT. LOOSE CONNECTIONS CAN CAUSE
TOO MUCH HEAT. THIS COULD DAMAGE THE BATTERY CHARGER AND THE
VARIABLE RESISTIVE LOAD.
(1) Preparation For Test
(a) Test Equipment Setup and Initial Settings:
1 Set the 115 V ac input source to OFF.
2 Remove the protective cover from Battery Charger Output Terminals (TB1).
3 Set up the test circuit as shown in Figure 1003.
NOTE: The 10,000 µF electrolytic capacitor must be temporarily disconnected

from the Variable Resistive Load to do the Overvoltage Protection Tests,
step (4)(a)3. When you set up the test circuit shown in Figure 1003,
make sure you can easily disconnect and reconnect this capacitor.
4 Set a block of solid material under each end of the Battery Charger to raise it
above the bench surface. This will let cool air flow up and around the Battery
Charger from the bottom.
(b) Do the steps that follow each time the Performance Tests are started or restarted. Also
set the initial switch positions and test equipment conditions that are given for each
Performance Test.
1 Make sure the 115 V ac input source is set to OFF.
2 Set the test circuit switches and equipment to the initial positions and conditions
as follows:
MODE SELECTOR Switch TR (A6J1 pin 8 not grounded)

BATTERY INTERLOCK Switch NORM (switch closed)
OVERCHARGE SWITCH NORM (switch closed)
PERCENT OVERCHARGE Switch 5%
BATTERY TEMP SIMULATOR 20.56 k (A6J1 pins 11 to 12)
(or Decade Resistor)
Variable Resistive Load; Two 2 resistors, three 10 resistors,
see Figure 1001 and set switches and one 25 resistor = about 0.75 
closed for the resistors that follow: (load resistance)
External Power Supply; 8.0 ± 2.0 V dc,
set current limit as follows: 15 ± 1 A
NOTE: *lf a solid-state load is used instead of the Variable Resistive Load, set
the load resistance to get 10 A load current before the 115 V ac input
source power is applied.
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EXTERNAL −
POWER SUPPLY
+ OSCILLOSCOPE
ISOLATION
DIODE
VARIABLE VAW
7.5 A DIGITAL
XFMRS METERS J1
TB1 MULTIMETER
PHASE A
4
PHASE B
115 VAC 7 + 2 AWG
VARIABLE
400 HZ PHASE C OUTPUT
10 TERMINALS RESISTIVE
3 PHASE N SHUNT
− 2 AWG LOAD
− +
2
ELECTROLYTIC
DIGITAL
CAPACITOR
MULTIMETER 10,000 μF
75 VDC
4-254
BATTERY
CHARGER
J1
OPEN
1 BATTERY
NORM INTERLOCK
3 SWITCH
5%
5 PERCENT
10% OVERCHARGE
6 SWITCH
560 OHMS 1/4 W
9 +
5 VDC
SHUTDOWN
POWER
ANNUNICATION
SUPPLY
LED
BATTERY
DECADE TEMP
11
RESISTOR SIMULATOR
OC
OVERCHARGE
NORM SWITCH
12
1M OHMS 1/4 W
TR
MODE
8
SELECTOR
CHARGE
SWITCH
4-254_04T0011B
Figure 1003
Battery Charger Test Circuit
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(c) Apply the dc output from the external power supply to the test circuit. (The current
through the shunt is about 10 A.)
(d) Set the 115 V ac input source to ON and apply it to the Battery Charger. Adjust the
Variable Transformers to give 115.0 ± 2 Vrms as measured at the PHASE A, PHASE B,
and PHASE C VAW meters. The Shutdown Annunciation LED should stay off if the
Battery Charger is serviceable.
Make sure the Shutdown Annunciation LED is off. If the Shutdown Annunciation LED
is OFF, adjust the load resistance for a load current of 38 ± 3.0 A.
If the Shutdown Annunciation LED comes on, do the fault isolation procedures that
follow and do the Preparation For Test procedures again:
1 Make sure the Battery Charger test circuit is set up correctly. Make sure the test
equipment is adjusted correctly.
2 Make sure J1 pin 9 is connected to the Shutdown Annunciation LED.
3 See Figure 1004, the Fault Isolation Chart, Sheet 7, TEST C.(2)(e).
(2) Input Current Balance
Set the MODE SELECTOR switch to CHARGE (A6J1 pin 8 grounded to the negative output
terminal). Adjust the load resistance to get an output voltage to 28 ± 1 V dc of 38.0 ± 3.0 A
load current. Measure the input current for each phase (PHASE A, PHASE B, and PHASE
C) with the VAW meters. The current shall be  3.2 A and  4.0 A.
If the input current is incorrect for any phase, do the fault isolation procedures that follow:
(a) If 115 V ac input source current is high (> 4.0 A), see Figure 1004, Sheet 3, TEST
C.(2)(a).
(b) If the Battery Charger load current comes on and goes off in cycles (current cycling),
see Figure 1004, Sheet 4, TEST C.(2)(b).
(c) If 115 V ac input source currents are not balanced, see Figure 1004, Sheet 5, TEST
C.(2)(c).
(d) If 115 V ac input source current is low (< 3.2 A), see Figure 1004, Sheet 6, TEST
C.(2)(d).
(e) If the Battery Charger is in shutdown mode (charger current is 0 A; external power
supply current is approximately 10 A at the load), see Figure 1004, Sheet 7, TEST
C.(2)(e).
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(3) Current Regulation
(a) Charge Mode
Set the MODE SELECTOR switch to CHARGE (A6J1 pin 8 grounded to negative
output terminal). Adjust the load resistance to get an output voltage of 28 ± 1 V dc and
load current of 38.0 ± 3.0 A. Monitor the load current while you adjust the Variable
Transformers to change the 115 V ac input source over a range of 105.0 – 121.0 Vrms.
Make sure the load current is 38.0 ± 3.0 A. Set the Variable Transformers to give 115.0
± 2 Vrms for each phase.
Adjust the load resistance to get an output voltage of 32 ± 1 V dc. Make sure the load
current is 38.0 ± 3.0 A. Adjust the load resistance to get an output voltage of
20.0 ± 0.5 V dc. Make sure the load current is 38.0 ± 3.0 A. Adjust the load resistance
to get an output voltage of 28 ± 1 V dc.
(b) Transformer Rectifier (TR) Mode
Set the MODE SELECTOR switch to TR (A6J1 pin 8 not grounded). Adjust the load
resistance to get an output voltage of 24.0 ± 0.5 V dc and a load current of
64.0 ± 3.0 A. Monitor the load current while you adjust the Variable Transformers to
change the 115 V ac input source over a range of 105.0 – 121.0 Vrms. Make sure the
load current is 64.0 ± 3.0 A. Set the Variable Transformers to give 115.0 ± 2 Vrms for
each phase.
Adjust the load resistance to get an output voltage of 20.0 ± 0.5 V dc. Make sure the
load current is 64.0 ± 3.0 A.
(4) Voltage Regulation and Ripple, T-R Mode
Make sure the MODE SELECTOR switch is set to TR (A6J1 pin 8 not grounded). Adjust the
load resistance to get a load current of 4.0 ± 0.5 A. Adjust the Variable Transformers to
increase the 115 V ac input source to 121 ± 0.5 Vrms. Make sure the output voltage is
27.75 ± 0.3 V dc. Make sure the ripple is  2.0 V p-p (peak to peak).
Adjust the load resistance to get a load current of 60.0 ± 1.0 A. Adjust the Variable
Transformers to decrease the 115 V ac input source to 105.0 ± 0.5 Vrms. Make sure the
output voltage is 27.65 ± 0.4 V dc. Make sure the ripple is  2.0 V p-p. Adjust the Variable
Transformers to give 115.0 ± 2 Vrms.
(a) Overvoltage Protection Tests
For Battery Chargers with P/N 4-254-03 and P/N 4-254-04, do the Overvoltage
Protection Test that follows. For Battery Chargers with P/N 4-254-02 and P/N 4-254-02
MOD 1, go to step 5 Battery Disconnect.
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1 Make sure the MODE SELECTOR switch is set to TR (A6J1 pin 8 not grounded).
Adjust the load resistance to get a load current of 4.0 ± 0.5 A. Monitor the output
voltage and adjust the Variable Transformers to increase the 115 V ac input
source to > 121 Vrms and  135 Vrms. Make sure the Battery Charger goes into
its shutdown condition (output voltage is < 10 V dc). Make sure the Shutdown
Annunciation LED is OFF.
NOTE: In this test circuit, when the Battery Charger does not supply output
power, there can be a current of approximately 2 A through the shunt.
This current is supplied by the external power supply and is indicated on
that power-supply current meter. The voltage (< 10 V dc) that is
measured at the Battery Charger Output Terminals is from the external
power supply.
2 Adjust the Variable Transformers to set the 115 V ac input source to

115 ± 2 Vrms. Make sure the Battery Charger comes out of its shutdown condition
(load current is 4.0 ± 0.5 A) within 15 seconds.
3 Refer to Figure 1003. Set the 115 V ac input source to OFF. Set the external
power supply to OFF. Wait one second for discharge to occur and disconnect the
10,000 µF electrolytic capacitor from the Variable Resistive Load.
4 Set the external power supply to ON. Set the 115 V ac input source to ON. Adjust
the Variable Transformers to set the 115 V ac input source to 115.0 ± 2 Vrms.
5 Adjust the load resistance to set an open-circuit condition (no load current)
across the Battery Charger Output Terminals. Make sure there is an output
voltage with an inverse-sawtooth waveform. Make sure this inverse-sawtooth
waveform has a peak of  32 V, a valley of  24 V, and a time period of 40 – 400
ms (as measured with the oscilloscope).
6 Refer to Figure 1003. Set the 115 V ac input source to OFF. Set the switches on
the Variable Resistive Load to get a load resistance of 0.75  . [See step (1)(b)2
to set the switches correctly.] Set the external power supply to OFF. Wait one
second for discharge to occur, and then connect the 10,000 µF electrolytic
capacitor to the Variable Resistive Load.
7 Set the external power supply to ON. Set the 115 V ac input source to ON. Adjust
the Variable Transformers to set the 115 V ac input source to 115.0 ± 2 Vrms.
(5) Battery Disconnect
(a) Make sure the MODE SELECTOR switch is set to TR (A6J1 pin 8 not grounded).
Adjust the load resistance to get a load current of 10 ± 2.0 A. Set the 115 V ac input
source to OFF.
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(b) Set the BATTERY INTERLOCK switch to OPEN (A6J1 pin 1 to 3). Set the 115 V ac
input source to ON. Make sure the Shutdown Annunciation LED comes on. Make sure
the Battery Charger goes into its shutdown condition (output voltage is < 10 V dc).
NOTE: In this test circuit, when the Battery Charger does not supply output power,
there can be a current of approximately 3 A through the shunt. This current is
supplied by the external power supply and is indicated on the external power
supply current meter. The voltage (< 10 V dc) that is measured at the Battery
Charger Output Terminals is from the external power supply.
(c) Set the BATTERY INTERLOCK switch to NORM (A6J1 pin 1 and 3). Make sure that
the Shutdown Annunciation LED goes OFF. Make sure the Battery Charger load
current is 10 ± 2 A and the output voltage is 27.75 ± 0.3 V dc. Do the battery
disconnect test that follows:
1 Set the 115 V ac input source to OFF. Make sure the Shutdown Annunciation
LED comes on. Adjust the external power supply voltage to 0.0 V dc to simulate a
disconnected battery. Set the 115 V ac input source to ON. Make sure the
Shutdown Annunciation LED goes OFF. Make sure the Battery Charger does not
supply output power (output voltage is < 1 V dc).
2 Slowly increase the external power supply voltage to 4 ± 1.0 V dc. Make sure the
Battery Charger output voltage is 27.75 ± 0.30 V dc.
(6) Overtemperature Protection

(a) Make sure the MODE SELECTOR switch is set to TR (A6J1 pin 8 not grounded). Set
the 115 V ac input source to OFF. Adjust the external power supply to
27.75 +0.00/-0.25 V dc. Set the 115 V ac input source to ON. Set the BATTERY TEMP
SIMULATOR resistance (decade resistor) to 660  .
(b) Decrease the BATTERY TEMP SIMULATOR resistance (decade resistor) in

increments of 10  from 660  . Make sure the Shutdown Annunciation LED comes on
when BATTERY TEMP SIMULATOR resistance (decade resistor) is between 560 
and 460  . Record the BATTERY TEMP SIMULATOR resistance (decade resistor)
when the Shutdown Annunciation LED comes on.
NOTE: The BATTERY TEMP SIMULATOR resistance (decade resistor) of 560  is
equivalent to 140 °F battery temperature, and 460  is equivalent to 150 °F.
(c) Adjust the external power supply to give 8 ± 2 V dc (measured at the external power-
supply voltmeter). Make sure the Battery Charger is in shutdown mode (output voltage
is < 10 V dc).
(d) Set the 115 V ac input source to OFF. Adjust the external power supply to
27.75 +0.00/-0.25 V dc. Set the 115 V ac input source to ON. Increase the BATTERY
TEMP SIMULATOR resistance (decade resistor) in 10  increments. Make sure that
Shutdown Annunciation LED goes OFF when the BATTERY TEMP SIMULATOR
resistance (decade resistor) gets 50 -175  higher than the resistance recorded in
step (6)(b). Adjust the external power supply to give 8 ± 2 V dc. With the Shutdown
Annunciation LED off, make sure the load current is 10 ± 2 A, and the output voltage is
27.75 ± 0.3 V dc.
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(7) Charge Cycle
(a) Inflection Point Voltage
1 Set the 115 V ac input source to OFF. Set the external power supply to
8.0 ± 2.0 V dc and its current limit to 15 ± 1 A. Set the MODE SELECTOR switch
to CHARGE (A6J1 pin 8 grounded to the negative output terminal). Adjust the
BATTERY TEMP SIMULATOR resistance (decade resistor) to 2.25 k . Set the
switches on the Variable Resistive Load to get a load resistance of 0.75  . [See
step (1)(b)2 to set the switches correctly.]
Set the 115 V ac input source to ON. Adjust the load resistance to get an output
voltage of 29.5 ± 0.5 V dc. Slowly adjust the external power supply to 30.5 V dc
as measured at its voltmeter. Set the 115 V ac input source to OFF and start the
stopwatch. After at least 20 seconds, stop the stopwatch and set its time to zero.
The procedure that follows (from the start of external power-supply adjustment
until the Battery Charger output voltage shows a high-to-low change) must be
done within 10 seconds.
a Set the 115 V ac input source to ON and start the stopwatch.
b Monitor the Battery Charger output voltage for the highest voltage and
slowly increase the external power-supply voltage (as measured at its
voltmeter).
Record the highest Battery Charger output voltage (at the Output Terminals)
before it decreases to 27.75 ± 0.3 V dc. Make sure the highest Battery Charger
output voltage is 31.2 ± 0.6 V dc (the inflection point). Make sure the external
power supply goes into current limit condition (15 ± 1 A at the external power-
supply ammeter).
2 Decrease the external power supply voltage to 26.0 ± 1.0 V dc (measured at the
external power-supply voltmeter).
Increase the external power-supply current limit to  35 A. Adjust the external

power-supply voltage to give 25 – 30 A (at the external power-supply ammeter).
Set the 115 V ac input source to OFF for more than 1 second. Set the 115 V ac
input source to ON. Make sure the Battery Charger output voltage is
29 ± 0.5 V dc and the external power-supply current is 0 A (at the external power-
supply ammeter).
Open the switch for one of the 10  resistors in the variable resistive load. Make
sure the Battery Charger output voltage changes to 27.75 ± 0.3 V dc. (This
change to the output voltage can occur immediately or it can take some minutes.)
Decrease the external power-supply voltage to 8 ± 2.0 V dc (measured at the

external power-supply voltmeter). Set its current limit to 15 ± 1 A (at the external
power-supply ammeter).
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(b) Proportional Timed Overcharge, 5%
Set the 115 V ac input source to OFF. Set the OVERCHARGE SWITCH to OC (switch
open). Set the PERCENT OVERCHARGE switch to 5% (A6J1 pin 5 open to pIn 6). Set
the MODE SELECTOR switch to CHARGE (A6J1 pin 8 grounded to negative output
terminal). Adjust the BATTERY TEMP SIMULATOR resistance (decade resistor) to
2.25 k .
Set the 115 V ac input source to ON. Adjust the load resistance for an output voltage of
32.5 ± 0.5 V dc.
Set the 115 V ac input source to OFF and start the stopwatch. After at least 20
seconds, stop the stopwatch and set its time to zero. Set the 115 V ac input source to
ON. Start the stopwatch.
After 300 ± 5 seconds (5 minutes), set OVERCHARGE SWITCH to NORM (switch

closed). After another 13 – 17 seconds on the stopwatch, make sure the Battery
Charger output voltage goes to 27.75 ± 0.3 V dc.
(c) Proportional Timed Overcharge, 10% [12% for all Battery Chargers with serial
numbers (SN) 232 and above].
NOTE: Do the Setup Procedure that follows only if the test equipment setup, switch
positions, or test equipment conditions have changed from those for test (7)(b)
(Proportional Timed Overcharge, 5%). If it is not necessary to do this Setup
Procedure, then only do the Test Procedure.
1 Setup Procedure (see NOTE above):
Set the 115 V ac input source to OFF. Set the OVERCHARGE SWITCH to OC
(switch open). Set the PERCENT OVERCHARGE switch to 10% (A6J1 pins 5
and 6 shorted together). Set the MODE SELECTOR switch to CHARGE (A6J1
pin 8 grounded to negative output terminal).
Adjust the BATTERY TEMP SIMULATOR resistance (decade resistor) to

2.25 k .
Set the 115 V ac input source to ON.
Adjust the load resistance for an output voltage of 32.5 ± 0.5 V dc.
Test Procedure:
Set the OVERCHARGE SWITCH to OC (switch open). Set the PERCENT

OVERCHARGE switch to 10% (A6J1 pins 5 and 6 shorted together).
NOTE: For all Battery Chargers with serial numbers SN 232 and above, the percent
overcharge will be 12% when the PERCENT OVERCHARGE switch is set to
10%.
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Set the 115 V ac input source to OFF and start the stopwatch. After at least 20
seconds, stop the stopwatch and set its time to zero. Set the 115 V ac input source to
ON. Start the stopwatch.
After 300 ± 5 seconds (5 minutes), set OVERCHARGE SWITCH to NORM (switch

closed). After another 33 – 39 seconds (26 – 39 seconds for all Battery Chargers with
serial numbers below SN 232), make sure the output voltage goes to 27.75 ± 0.3 V dc.
Set the 115 V ac input source to OFF.
NOTE: It is only necessary to do the Charge Cycle Initiation tests that follow [given in
paragraphs (d), (e), and (f)] once (the first time) after the Battery Charger is
modified by SB4-254-24-10 to P/N 4-254-02 MOD1 or to P/N 4-254-04.
(d) Charge Cycle Initiation, Battery Voltage Low
Only do this Charge Cycle Initiation test if the Battery Charger has just been modified
by SB4-254-24-10 to P/N 4-254-02 MOD1 or to P/N 4-254-04.
1 Set the external power supply to 8.0 ± 2.0 V dc. Set the MODE SELECTOR
switch to CHARGE (A6J1 pin 8 grounded to the negative output terminal). Set the
OVERCHARGE SWITCH to NORM (switch closed).
2 Set the 115 V ac input source to ON. Adjust the Variable Transformers to give
115 ± 2 Vrms.
3 Monitor the Battery Charger output voltage. Adjust load resistance for
approximately 10 A load current. When the output voltage is 27.75 ± 0.3 V dc and
does not change, adjust the load resistance to get a load current of > 35 A and
< 41 A.
4 Monitor the Battery Charger output voltage. Adjust the load resistance until the
output voltage is 20 – 22.0 V dc.
5 Set the OVERCHARGE SWITCH to OC (switch open). Monitor the Battery

Charger output voltage and load current. Slowly adjust the load resistance to
increase the output voltage. Make sure the Battery Charger meets the
specifications that follow:
a Output voltage increases to > 30 V dc.
b Load current is > 35 A and < 41 A.
(e) Charge Cycle Initiation, Charge-Mode Control Interrupted
1 Set the external power supply voltage to 8.0 ± 2.0 V dc. Make sure the MODE
SELECTOR switch is set to CHARGE (A6J1 pin 8 grounded to the negative
output terminal). Set the OVERCHARGE SWITCH to NORM (switch closed).
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2 Monitor the Battery Charger output voltage. Adjust load resistance for about 10 A
load current. When the output voltage is 27.75 ± 0.3 V dc and does not change,
adjust the load resistance to get a load current of > 35 A and < 41 A.
4 Set the OVERCHARGE SWITCH to OC (switch open). Set the MODE

SELECTOR switch to TR (A6J1 pin 8 not grounded) for 500 milliseconds or
more, then set the MODE SELECTOR switch to CHARGE (A6J1 pin 8 grounded
to the negative output terminal).
5 Monitor the Battery Charger output voltage and load current. Slowly adjust the
load resistance to increase the output voltage. Make sure the Battery Charger
meets the specifications that follow:
(f) Charge Cycle Initiation When AC Input Power Interrupted
1 Set the external power supply voltage to 8.0 ± 2.0 V dc. Make sure the MODE
SELECTOR switch is set to CHARGE (A6J1 pin 8 grounded to the negative
output terminal). Set the OVERCHARGE SWITCH to NORM (switch closed).
2 Monitor the Battery Charger output voltage. Adjust load resistance for
approximately 10 A load current. When the output voltage is 27.75 ± 0.3 V dc and
does not change, adjust the load resistance to get a load current of > 35 A and
< 41 A.
4 Set the OVERCHARGE SWITCH to OC (switch open). Set the 115 V ac input
source to OFF for 500 ms or more. Set the 115 V ac input source to ON.
5 Monitor the Battery Charger output voltage and load current. Slowly adjust the
load resistance to increase the output voltage. Make sure the Battery Charger
meets the specifications that follow:
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(8) Performance Tests Completion
Do the procedures that follow to complete the Performance Tests:
(a) Set the OVERCHARGE SWITCH to NORM (switch closed).
(b) Set the 115 V ac input source to OFF and disconnect it from the Battery Charger.
(c) Set the external power supply to OFF and disconnect it from the Battery Charger.
(d) Put the protective cover on the Battery Charger Output Terminals.
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2. Fault Isolation
See Figure 1004 for the Fault Isolation Charts. The paragraphs that follow give instructions to do fault
isolation of the Battery Charger.
NOTE: In the paragraphs that follow, the IPL figure and item identification numbers are given in
parentheses to help with part number identification. The format is as follows: (Figure Number -
Item Number). For example: the top cover (1-5) of the Battery Charger is given IPL Figure 1
and Item Number 5.
A. Fault Isolation Chart
Each fault isolation procedure is given as a Fault Isolation Chart. The Fault Isolation Chart gives
the test paragraph number of the related Pre-performance Test or Performance Tests [for
example: TEST C(2)(a)]. Typically, the first part of each Fault Isolation Chart gives the failure
condition with an instruction to check or test for the most probable failure. Then, the chart
branches into a test OK branch and a test Not OK branch. There are as many test OK branches
and test Not OK branches as necessary to isolate the failure.
When fault isolation shows a circuit or component failure, only the most probable circuit or
component failures are given. Then, the most probable failed circuit or component is identified by
its equipment designator. Repair instructions tell which circuit or component must be replaced. It
may be necessary to do the fault isolation procedure again if there is more than one failure. Also,
the technician may need to do other fault isolation procedures that are typical for a repair shop.
B. Fault-Isolation Chart Sequence
The sequence of the Fault Isolation Charts is the same as the sequence of the Pre-performance
Tests and Performance Tests. Start the fault isolation procedure from the first test that failed.
C. Schematics and Circuit Function Illustrations
The Battery Charger Schematic Diagram is provided in Figure 2001. Output voltage curves,
integrated block diagrams and inverter control waveform sequences are shown in front of the
theory of operation, Figure 1 through Figure 7.
WARNING: USE HIGH-VOLTAGE AND HIGH-CURRENT SAFETY PRECAUTIONS DURING

BATTERY CHARGER OPERATION WITH THE TOP COVER REMOVED. THE
BATTERY CHARGER GETS HIGH INPUT AC VOLTAGES AND CURRENTS DURING
OPERATION. IT ALSO SUPPLIES HIGH DC LOAD CURRENT DURING OPERATION.
REMOVAL OF THE TOP COVER DURING OPERATION OF THE BATTERY CHARGER
CAN PUT THE TECHNICIAN IN CONTACT WITH DANGEROUS VOLTAGE AND
CURRENT. FAILURE TO USE THESE PRECAUTIONS COULD CAUSE INJURY OR
DEATH.
D. Preparation of Battery Charger
Partial disassembly of the Battery Charger is necessary to do some of the fault isolation
procedures. Remove the top cover (1-5) and the bottom cover (1-15). This will give access to test
points at terminals E1, E2 and E4 on the A2 assembly. It will also give access to test points on the
A3A1 and A3A2 circuit boards, and other test points.
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The A3A1 and A3A2 test points are brought out to the board-edge connector of each circuit board
in the 4-254-02/-02 MOD1 configuration. These test points are only available on each circuit
board in the 4-254-03/-04 configuration.
E. Optional Circuit Board Breakout
Removal of the rear heat-sink assembly (1-270) is necessary to do fault isolation on the A3A1
(1-290) and A3A2 (1-285). Use the procedure that follows to remove the rear heat-sink assembly
(1-270) with A3A1 (1-290) and A3A2 (1-285) circuit boards attached.
(1) Remove screws (1-30) from mounting strip (1-25) on side heat sinks. Do not remove the
rear screws from the rear heat sink (1-305).
(2) Remove screws (1-280) holding rear heat sink (1-305) to rear edge of side (finned) heat
sinks.
CAUTION: TO DISCONNECT OR CONNECT THE J1 CONNECTORS, ONLY TURN EACH

SCREW ONE COMPLETE TURN AT A TIME. THESE J1 CONNECTORS ON THE
A3A1 AND THE A3A2 CIRCUIT BOARDS ARE EASILY DAMAGED. FAILURE TO
FOLLOW THIS PRECAUTION COULD DAMAGE ONE OR BOTH J1
CONNECTORS.
(3) Disconnect the connectors (3-25 and 4-25) to A3A1 and A3A2 and separate the heat sink
assembly from the Battery Charger.
(4) Remove screws (1-288; see IPL Figure 1, sheet 5) that attach resistors R90 and R91
(4-235) and ground lugs from rear heat sink (1-305).
(5) To separate the two circuit boards for access to A3A2, remove 12 screws (1-300) that attach
the circuit boards to rear heat sink plate. On the bottom row of screws, remove only the
outer two screws and the one center screw.
NOTE: Be careful to identify and retain screws (1-300) removed in this step.
(6) Connect jumpers between the long circuit-board pins and the related circuit board sockets.
NOTE: Do not operate the Battery Charger with A3A1 and A3A2 connected together by
extender cables. The wiring length of the cables increases electromagnetic
interference susceptibility, and the circuits will not operate correctly.
(7) Connect the connectors (3-25 and 4-25) to A3A1 and A3A2. Set the two circuit boards on
rigid insulating material at the rear, and level with the top, of the Battery Charger.
(8) Use short jumpers to connect the two chassis ground connections.
Page 1019
24-31-04 May 25/12
4-254
TEST B(1) (a)
INSULATION RESISTANCE LESS THAN 10 MEGOHMS, INPUT

TO OUTPUT. DISCONNECT A2A1P1 FROM A3A2. IF
OK - REPLACE A2A1T1, A2A1T2,

NOT OK - REMOVE CONNECTIONS
A2A1T3, OR A2A1T4.
A2A1-E3 (RED WIRE ON INDUCTOR
BOARD) AND A1A2-E2 (WHITE WIRE
ON INPUT ASSEMBLY). IF
NOT OK - DISCONNECT OK - REPLACE

A6P1 FROM A3A1. IF A4T1.
OK - REPLACE A1T1.
TEST B(1) (b)

INSULATION RESISTANCE LESS THAN 10 MEGOHMS, INPUT

TO CHASSIS. REMOVE GROUNDING WIRES FROM INPUT
ASSEMBLY A1L1 PIN 7. IF
NOT OK - DISCONNECT TERMINAL OK - REPLACE A1C1, 2 OR 3,

LUGS FROM INPUT ASSEMBLY A1A2 E1, OR A1A1C1, 2 OR 3.
2 AND 4. IF
NOT OK - REPLACE A1CR1,

A1L1, A1T1, A1L2/L4 OR A1L3. OK - REPAIR A2Q1/Q2 INSULATOR TO
CHASSIS SHORT ON SIDE HEAT SINK,
REPLACE A4T1, OR REPLACE A1L1.
IF NOT OK - PINCHED OR BRAIDED

WIRE TO CHASSIS.
4-254_U0011_EX-FIG 106

Fault Isolation Chart
Page 1020
24-31-04 May 25/12
4-254
TEST B(1) (c)
INSULATION RESISTANCE LESS THAN

10 MEGOHMS, OUTPUT TO CHASSIS.
DISCONNECT GROUND LUG FROM A3A1,
A3A2 AT CHASSIS. IF
NOT OK - DISCONNECT OK - REPLACE A3A1

A2A1P1 FROM A3A2. IF C29 OR A3A2C31.
NOT OK - REMOVE OK - REPLACE A2A1

A6P1 FROM A3A1. IF T1, 2, 3 OR 4
OK - REPLACE A1T1, OR CHECK FOR

SHORT OF CIRCUIT BOARD FOIL TO
METAL STANDOFF, OR INSULATOR
BETWEEN A3A1 U9 AND Q1 TO CHASSIS.
NOT OK - DISCONNECT
OUTPUT WIRES FROM
A4L1 AND A4A1 RECTIFIER
BLOCK ASSEMBLY TO A5
(OUTPUT FILTER). IF
OK - REPLACE A4C31, REPLACE
INSULATOR BETWEEN A4A1
RECTIFIER BLOCK AND CHASSIS,

NOT OK - REPLACE A5 REPLACE A4A1 OR A4L1.
TEST B(3)
REVERSE CURRENT FAILS. IF
BELOW 18mA, REPLACE ABOVE 35mA - REMOVE A6P1

A4A1CR1 OR CR2. FROM A3A1 AND RECHECK. IF
OK - REMOVE A3A1 AND CHECK NOT OK - DISCONNECT LUGS A4A1

FOR COMPONENT SHORT BETWEEN DIODE BLOCK TO A5; RECHECK
A3A1J1 PIN 1 TO PIN 15. REVERSE CURRENT. IF
OK - REMOVE EITHER GREEN WIRE TO A4A1CR1/CR2. NOT OK - CHECK COMPONENTS

CHECK COMPONENTS A4A1C1/2; A4A1CR1/CR2 WITH A5A1C1/C2/C3 FOR SHORT.
OHMMETER. CR1/CR2 SHOULD READ >150k OHMS
(REVERSE) ON x 10k SCALE.
4-254_U0012_EX-FIG 106

Page 1021
24-31-04 May 25/12
4-254
TEST C(2) (a)
INPUT CURRENT ABOVE 4.0 AMP.

CHECK A1CR1 FRONT-TO-BACK
RESISTANCE RATIO AS BELOW. IF
OK - CHECK FOR SHORTED NOT OK - REPLACE A1CR1.

CAPACITOR A1A2C1-C8. IF
NOT OK - REPLACE DEFECTIVE CAPACITOR.
OK - REPLACE A3A2. CHARGE CURRENT

CALIBRATION MAY BE TOO HIGH.
A1CR1 DIODE TEST
FROM TO AND TO
POS LEAD NEG LEAD READ NEG LEAD READ

A6J1-4* A1E1 <200 A1E4 >10K
A6J1-7* A1E1 <200 A1E4 >10K
A6J1-10* A1E1 <200 A1E4 >10K
NEG LEAD POS LEAD READ POS LEAD READ

A6J1-4* A1E1 >10K A1E4 <200
A6J1-7* A1E1 >10K A1E4 <200
A6J1-10* A1E1 >10K A1E4 <200
* NOTICE ANY UNBALANCE IN READINGS
4-254_U0013_EX-FIG 106

Page 1022
24-31-04 May 25/12
4-254
TEST C(2) (b)
CURRENT CYCLING ON/OFF. DEENERGIZE UUT,

DISCONNECT WIRES FROM A1A2 INPUT ASSEMBLY
TERMINALS E1, E2 AND E4. WITH OHMMETER ON
HIGHEST SCALE, MEASURE (POSITIVE) LEAD
FROM A1A2 E1 (BLUE WIRE) TO (NEGATIVE) LEAD
FROM A1A2 E2. IF
NOT SHORTED - MEASURE (POSITIVE) SHORTED - REPLACE A2Q1

LEAD FROM A1A2 E2 TO (NEGATIVE) OR A2A1CR2 *
LEAD FROM A1E4. IF
SHORTED - REPLACE A2Q2

OR A2A1CR3 *
OK - RECONNECT LEADS, PREPARE UNIT TO APPLY * FORWARD TO REVERSE RATIO

POWER. OPEN BATTERY INTERLOCK SWITCH. SHOULE BE <400 TO >50k ,
MEASURE VOLTAGE BETWEEN A1A2 E2 TO E1; MEASURED WITH ANALOG METER
COMPARE TO MEASUREMENT A1A2 E2 TO E4. IF (SIMPSON OR TRIPLETT).
OK - MEASURE VOLTAGE ON A1T1 TERMINALS 7 TO 8 NOT OK - REPLACE A1A2

(ORANGE AND YELLOW WIRES). SHOULD BE 20 R1 OR R2, C1-C8.
TO 28Vdc; NOMINAL 26Vdc. IF
NOT OK - CHECK FRONT

OK - REPLACE A3A2, OR CHECK AMPLITUDE AND TO BACK RATIO
BALANCE OF PULSES AS BELOW; ON A3A2: A1CR2-CR7. IF
TP3/4 (NOT OK - SUSPECT A3A2Q1, Q2, U1)
TP14/15 (NOT OK - SUSPECT A3A2U5)
OK - REPLACE
TP9/17 (NOT OK - SUSPECT A3A2U7, Q10, Q14) NOT OK - REPLACE
A1T1.
TP10/13 (NOT OK - SUSPECT A3A2U7, U8, Q20, A1CR2- CR7.
Q19, U4, U6)
TP11/12 (NOT OK - SUSPECT A3A2U8, Q15, Q16,
U4, U6)
NOTE: FOR MORE DIRECT FAULT ISOLATION,
REPLACE A3A2. IF FAULT IS CORRECTED,
AND FAULT ISOLATION ON THE A3A2 IS
DESIRED, REINSTALL DEFECTIVE A3A2
AND FOLLOW ABOVE PROCEDURE.
IF OK (A3A2 NOT DEFECTIVE), REPLACE A3A1.
4-254_U0014_EX-FIG 106

Page 1023
24-31-04 May 25/12
4-254
TEST C(2) (c)
INPUT CURRENT IS UNBALANCED (LESS THAN 3.2A,

OR MORE THAN 4.0 A ON A PHASE) - ADJUST VARIABLE
TRANSFORMERS TO PROVIDE EXACTLY THE SAME
VOLTAGE TO EACH INPUT LINE OR
ROTATE THE INPUT CONNECTIONS. IF
OK (EACH PHASE IS WITHIN 5% OF THE NOT OK - DEENERGIZE UUT. REMOVE WIRES

AVERAGE OF 3 PHASES OR UNBALANCE TO A1T1 TERMINALS 1, 2 AND 3. WITH OHMMETER,
MOVED TO DIFFERENT PHASE) UUT IS NOT MEASURE FORWARD/ REVERSE DIODES OF
DEFECTIVE. A1CR1 AS BELOW. IF
NOT OK - REPLACE A1CR1

OK - WITH WIRES TO A1T1 TERMINALS
REMAINING OFF, APPLY OHMMETER TO
A1C1, C2 AND C3, AND NOTICE WHETHER
METER INDICATES EACH CAPACITOR
CHARGES. IF
NOT OK - REPLACE
OK - (EACH CAPACITOR A1C1, C2 OR C3.
CHARGES) - MEASURE
CONTINUITY A1T1 1-3,
1-2, 2-3 AND A1L1 1-2,
3-4, 5-6.
A1CR1 DIODE TEST
FROM TO AND TO
POS LEAD NEG LEAD READ NEG LEAD READ

A6J1-4* A1E1 <200 A1E4 >10K
A6J1-7* A1E1 <200 A1E4 >10K
A6J1-10* A1E1 <200 A1E4 >10K
NEG LEAD POS LEAD READ POS LEAD READ

A6J1-4* A1E1 >10K A1E4 <200
A6J1-7* A1E1 >10K A1E4 <200
A6J1-10* A1E1 >10K A1E4 <200
* NOTICE ANY UNBALANCE IN READINGS
NOTE: TEST FAILURE INDICATION MAY BE CAUSED BY ONE PHASE FROM POWER SOURCE
LOW OR SLIGHTLY OUT OF PHASE, OR BY NON-SINUSOIDAL INPUT POWER.
4-254_U0015_EX-FIG 106

Page 1024
24-31-04 May 25/12
4-254
TEST C(2) (d)
INPUT CURRENT IS <3.2 A VERIFY

APPROXIMATELY 270Vdc A1E1 TO A1E4. IF
OK - MEASURE A1T1 TERMINAL 7 AND 8

(ORANGE AND YELLOW WIRES) FOR NOT OK - CHECK CONTINUITY OF POWER
APPROXIMATELY 26Vdc. IF TRAIN COMPONENTS A1L1, L2, L4, L3, R3.
OK - IS INPUT CURRENT CYCLING NOT OK - CHECK FOR OPEN

ON/OFF. IF A1T1 OR A1CR2-CR7.
YES - SEE CURRENT CYCLING NO - IS CURRENT SHUTDOWN

TROUBLESHOOTING CHART (NO OUTPUT). IF
C(2) (b).
YES - SEE CURRENT SHUTDOWN NO - SEE CURRENT REGULATION

TROUBLESHOOTING CHART TROUBLESHOOTING CHART
C(2) (e). C(3) (b).
4-254_U0016_EX-FIG 106

Page 1025
24-31-04 May 25/12
4-254
TEST C(2) (e)
OUTPUT CURRENT SHUTDOWN - CURRENT IS ZERO.

MEASURE VOLTAGE A1T1 TERMINALS 7 AND 8
(ORANGE AND YELLOW WIRES). VOLTAGE SHOULD
BE 22 TO 28Vdc (26Vdc NOMINAL). IF
NOT OK - CHECK FRONT TO BACK RATIO,

A1CR2 - CR8, OR REPLACE A1T1.
OK - REPLACE A3A1, OR MEASURE

20Vdc ON A3A1TP1. IF
OK - REPLACE A3A2, OR MEASURE NOT OK - SUSPECT A3A1 U9, VR2,

5Vdc ON A3A2TP6. IF VR6, C14, C16.
NOT OK - CHECK A3A1Q1 BY

STANDARD METHODS. IF
OK - MEASURE 2.5Vdc REFERENCE ON OK - REPLACE NOT OK -

A3A1TP6. IF A3A2U1 REPLACE A3A1Q1
OK - MEASURE 5Vdc ON A3A2TP1. IF NOT OK - SUSPECT

A3A1VR5
OK - REPLACE A3A2, OR MEASURE FOR NOT OK - REPLACE A3A1, OR

5Vdc ON A3A2TP18. IF MEASURE > 5Vdc ON A3A1TP4. IF
NOT OK - SUSPECT NOT OK - SUSPECT

A3A2U3, U2 A3A1U1, C17
OK - MEASURE >5Vdc
OK - MEASURE AMPLITUDE AND BALANCE ON A3A1TP2. IF
OF PULSES AS BELOW ON A3A2:
TP3/4 (NOT OK - SUSPECT Q1, 2, U1, U2) OK - MEASURE <0.5Vdc

TP14/15 (NOT OK - SUSPECT U5) ON A3A1TP5. SUSPECT
TP9/17 (NOT OK - SUSPECT U7, Q10, Q14) A3A1 U3, U1, Q8.
TP10/13 (NOT OK - SUSPECT U4, U6-8, Q19,
Q20)
TP11/12 (NOT OK - SUSPECT U4, U6, U8,
Q15, Q16)
NOT OK - SUSPECT
A3A1Q3, R9, U2
4-254_U0017_EX-FIG 106

Page 1026
24-31-04 May 25/12
4-254
TEST C(3) (a)
CURRENT REGULATION (TR MODE) FAILS.

CHECK FOR PINCHED OR BROKEN WIRE
A6J1 PIN 8 TO A6P1 PIN 10. IF OK, DOES
CURRENT REGULATE AT 38A.
YES - SUSPECT NO - IS CURRENT, AND

A3A2Q5/Q6 SHORT. VOLTAGE, LOW.
YES - SUSPECT A3A2Q18 SHORT,

A3A1U2 DEFECTIVE, A3A2U1 DEFECTIVE,
OR A3A2Q3/Q4 DEFECTIVE.
NOTE: PREFERRED ORDER OF BOARD REPLACEMENT: 1. A3A2 2. A3A1
TEST C(3) (b)

CURRENT REGULATION (CHARGE MODE) FAILS.

CHECK FOR PINCHED OR BROKEN WIRE A6J1
PIN 8 TO A6P1 PIN 10. IF OK, DOES
CURRENT GO TO 64A BEFORE REGULATING.
YES - SUSPECT NO - IS CURRENT, AND

A3A2Q5/Q6 OPEN VOLTAGE, LOW.
NO - IS CURRENT
YES - SUSPECT A3A2 REGULATING HIGH.
Q18 SHORT, U1 DEFECTIVE
YES - SUSPECT
A3A2Q17/18 OPEN NO - VOLTAGE IS REGULATING AT SUSPECT
27.75Vdc. SUSPECT A3A1:
Q11 OPEN, U2 DEFECTIVE, Q10 SHORTED.
4-254_U0018_EX-FIG 106

Page 1027
24-31-04 May 25/12
4-254
TEST C(4) (a)
VOLTAGE REGULATION AND RIPPLE, TR MODE. CHECK FOR PINCHED OR

SHORTED WIRE A6J1 PIN 8 TO A6P1 PIN 10, AND PINCHED OR BROKEN WIRE
A6P1 PIN 7 AND PIN 15 TO A4 AND A5. IF OK, IS FAILURE:
VOLTAGE REGULATION: * RIPPLE VOLTAGE EXCESSIVE.

SUSPECT A5C1-3 OPEN,
SUSPECT: A3A1U2 DEFECTIVE,
A4L1 SHORTED, A4CR1/2 OPEN,
A3A1Q11 SHORTED,
A3A2 DEFECTIVE.
A3A1Q10 OPEN,
A3A2 R96 OPEN**
A3A2CR37 OPEN,
A3A2 C40 OPEN**
A3A2Q6/Q5 SHORTED,
A3A2U1 DEFECTIVE.
A3A2R94 OPEN**
A3A2R93 OPEN**
A3A2C9 SHORTED**
* FIRST, CHECK FOR INADEQUATE CONNECTION OR

TIGHTENING OF OUTPUT CURRENT CARRYING CONNECTIONS.
** 4-254-03 AND 4-254-04

TEST C(4) (b)
VOLTAGE REGULATION, TR MODE, AT NO LOAD (4-254-03)
NO SAWTOOTH WAVEFORM AT NO LOAD:
SUSPECT: A3A2R93 OPEN

A3A2R32 OPEN
A3A2R94 OPEN
A3A2C39 SHORT
4-254_U0019_EX-FIG 106

Page 1028
24-31-04 May 25/12
4-254
TEST C(5) (b)
BATTERY DISCONNECT (INTERLOCK) TEST FAILS. CHECK FOR

PINCHED OR SHORTED WIRE A6J1 PINS 1 AND 3 TO A6P1 PINS 6
AND 13. IF OK, DOES SHUTDOWN ANNUNCIATE.
YES - DOES OUTPUT NO - DOES OUTPUT CURRENT

CURRENT SHUTDOWN. SHUTDOWN.
YES - SUSPECT
NO - MEASURE A3A2TP1, A3A1Q2 SHORTED.
SHOULD BE LOW. IF
NO - SUSPECT
OK - SUSPECT NOT OK - SUSPECT A3A1Q3 OR CR10
A3A2Q1 OPEN. A3A1CR7 OPEN. OPEN.
YES - IS SHUTDOWN
CONTINOUS. SUSPECT
A3A1Q3 SHORTED OR
A3A1U2 PIN 12/13/14

CIRCUIT DEFECTIVE
(PIN 14 CONTINUAL HIGH).
TEST C(5) (c)
BATTERY DISCONNECT TEST FAILS WHEN

POWER CONNECTOR OFF. TEST C(5) (b)
PERFORMED PROPERLY. SUSPECT
A3A1CR27 OPEN.
4-254_U0110_EX-FIG 106

Page 1029
24-31-04 May 25/12
4-254
TEST C(6)
OVERTEMPERATURE PROTECTION TEST FAILS -
OVERTEMPERATURE SHUTDOWN OCCURS:
WHEN THERMISTOR SIMILATOR

WHEN THERMISTOR SIMULATOR
RESISTANCE IS TOO HIGH.
RESISTANCE IS TOO LOW.
SUSPECT A3A1: U2 PIN 2
SUSPECT A3A1: R20 OR R18 OPEN.
SHORTED, R11 OR R84 OPEN.
NO SHUTDOWN - SUSPECT CONTINUOUSLY OR NEARLY

A3A1: U2 DEFECTIVE, CONTINUOUSLY. SUSPECT

R11 OR R13 OPEN. A3A1: U2 FAILURE (PIN 14
HIGH) OR R20 OPEN.
NOTE: CHECK BATTERY TEMPERATURE SENSE WIRING IN CHASSIS.
4-254_U0111_EX-FIG 106

Page 1030
24-31-04 May 25/12
4-254
TEST C(7) (a)
INFLECTION POINT VOLTAGE TEST. DOES INFLECTION

OCCUR, BUT AT WRONG POINT.
YES - MEASURE 2.5Vdc NO INFLECTION OCCURS -

REFERENCE VOLTAGE SUSPECT A3A1: U2 PINS 1, 2 AND 3
AT A3A1TP8. IF DEFECTIVE, U8 DEFECTIVE, U7/U6
DEFECTIVE, Q11 SHORTED , Q6
SHORTED R11 OPEN, TP8 REFERENCE
VOLTAGE TOO HIGH.
OK - SUSPECT A3A1:
COMPONENTS R11, R18,
R19, C10.
NOT OK - SUSPECT
A3A1: VR4.
TEST C(7) (b)

PROPORTIONAL TIMED OVERCHARGE (5%) FAILS.
DOES OUTPUT VOLTAGE DROP TO 27.75Vdc,
BUT AT WRONG TIME INTERVAL.
YES - MEASURE OSCILLATOR TIME NO - OUTPUT VOLTAGE DOES NOT

ON A3A1TP9, SHOULD BE 180ms DROP TO 27.75Vdc. CHECK
DURING BASE CHARGE, 9ms OSCILLATOR AT A3A1TP9. IF
DURING OVERCHARGE. IF
OSCILLATING - CHECK NOT OSCILLATING -
OK - SUSPECT NOT OK - UP COUNT PULSES ON SUSPECT A3A1:
A3A1U6, U7 SUSPECT A3A1 A3A1TP12. IF Q6, U3, C23.
OR U8. U3, C23, Q4,
Q5, Q6.
OK - CHECK DOWN NOT OK - SUSPECT
COUNT PULSES ON A3A1 U4 AND U5.
A3A1TP11. IF
OK - SUSPECT A3A1: NOT OK - SUSPECT

U8, U6, U7. A3A1: U5, U8, CR5/6.
4-254_U0112_EX-FIG 106

Page 1031
24-31-04 May 25/12
4-254
TEST C(7) (c)
PROPORTIONAL TIMED OVERCHARGE (10%) FAILS.

TEST C(7) (b) PERFORMS PROPERLY. SUSPECT
A3A1: Q4 OPEN.
TEST C(7) (d)
CHARGE CYCLE INITIATION, BATTERY VOLTAGE <23 VOLTS

TEST FAILS. MEASURE 2.5Vdc REFERENCE ON A3A1TP8. IF
THIS PAGE
OK - SUSPECT A3A1: INTENTIONALLY NOT OK - SUSPECT
R21, C11, R26, U2 BLANK A3A1: VR4.
PINS 5, 6 AND 7.
TEST C(7) (e)
CHARGE CYCLE INITIATION, CHARGE MODE CONTROL

INTERRUPTED TEST FAILS. SUSPECT A3A1:
CR15, R12, C7, R15 AND C11.
TEST C(7) (f)
CHARGE CYCLE INITIATION - AC POWER INTERRUPTION TEST FAILS.

SUSPECT A3A1: C1, CR1, R71, R69, R68, U6 OR U7.
4-254_U0113_EX-FIG 106

Page 1032
24-31-04 May 25/12
4-254
SCHEMATICS AND WIRING DIAGRAMS
1. General
This section gives the interconnecting diagrams of circuit cards, chassis wiring, modules,
subassemblies, and external connector interconnections of the Battery Charger.
Page 2001
24-31-04 May 25/12
4-254
REVISION SERIAL NO.

CODE REVISION DESCRIPTION EFFECTIVITY
Increased wire sizes (was BLK 18, WHT 12, and RED 12) 493 and up1
1 and changed connection (BLK and WHT were
connected at E5).
2 Altered wire routing (was one wire, WHT 12, from T1-1 493 and up1
and R1/R2 to E2).
3 Altered wiring (was one wire from T2-3 and C1 to E25, 493 and up1
and one wire from T3-3 and C2 to E19).
4 Altered wiring (leads from T2-4, T2-11/13, R1, and CR2 493 and up1
were all shown connected to E24 with YEL 14 to Q1).
5 Altered wiring (leads from T3-4, T3-11/13, R2, and CR3 493 and up1
were all shown connected to E18 with YEL 14 to Q2).
1. All units with Terminal Board 4-254511-01 installed. Refer to ASSEMBLY.
Revision Reference Sheet for

Figure 2001 (Sheet 1)
4-254-02/-02 MOD1 Battery Charger Schematic/Wiring Diagram
Page 2002
24-31-04 May 25/12
4-254

4-254-02/-02 MOD1 Battery Charger Schematic/Wiring Diagram
Page 2003/2004
24-31-04 May 25/12
4-254
BLANK
THIS PAGE
INTENTIONALLY
24-31-04
Page 2005
May 25/12
4-254
REVISION SERIAL NO.

Deleted CR8 and R16 (120 k ) between pin 9 of U2B 115, 123, 127,
1 and junction of R45 and R31. Configuration of A3A1 131, and up
changed from 4-254253-01 to 4-254253-02 or 4-254353-01.
Deleted R64 (22kW) from collector of Q5. Configuration 115, 123, 127,
2 of A3A1 changed from 4-254253-01 to 4-254253-02 or 131, and up
4-254353-01.
Added C32, C31, CR30, and TP13. Configuration of 115, 123, 127,
3 A3A1 changed from 4-254253-01 to 4-254253-02 or and up
4-254353-01.
Configuration of A3A1 changed from 4-254253-01 to 115, 123, 127,

4 4-254253-02 or 4-254353-01. 131, and up
R65: Was 2.67 m , 1% (3-385)
Is Select in test/calibration,
0.1% (3-385A or 3-385C)
R33: Was 2.61 k , (3-285);
Is 2.00 k , (3-287A)
R18: Was 4.64 k , 1% (3-260);
Is 4.64 k , 0.1% (3-260A)
R25: Was 26.7 k , 1% (3-235);
Is 26.4 k , 1% (3-235A)
R59: Was 27.0 k , 2% (3-300);

Is 66.5 k , 0.1% (3-300A)
R62: Was 47 k , 5% (3-401);
Is 22.5 k , 0.1% (3-401B)
R34: Was 22 k , 5% (3-327);
Is 10 k , 0.1% (3-327A)
R21: Was 2.67 k , 1% (3-230);
Is 2.67 k , 0.1% (3-230A)
R11: Was 28.7 k , 1% (3-250);
Is 28.7 k , 0.1% (3-250A)
R58: Was 4.42 k , 1% (3-275);
Is 6.81  , 0.1% (3-275A)
R61: Was 7.68 k , 1% (3-280);
Is 5.23 k , 0.1% (3-280A)
5 Added C30 (3-215) 36, 39, 40, and on
Configuration of A3A1 changed from 4-254353-01 to All units 232 and

4-254353-02. on;
R58: Was 6.81 k , 0.1% (3-275A); interchangeable
6
Is 7.87 k , 0.1% (3-275C) on units prior
R61: Was 5.23 k , 0.1% (3-280A); to 232
Is 4.22 k , 0.1% (3-280C)

4-254-02 A3A1 Board Schematic Diagram
Page 2006
24-31-04 May 25/12
4-254

Page 2007/2008
24-31-04 May 25/12
4-254
BLANK
THIS PAGE
INTENTIONALLY
24-31-04
Page 2009
May 25/12
4-254
REVISION SERIAL NO.


4-254-02 MOD1 A3A1 Board Schematic Diagram
Page 2010
24-31-04 May 25/12
4-254

4-254-02 MOD1 A3A1 Board Schematic Diagram
Page 2011/2012
24-31-04 May 25/12
4-254
BLANK
THIS PAGE
INTENTIONALLY
24-31-04
Page 2013
May 25/12
4-254
REVISION SERIAL NO.

1 Deleted R89 (3-345) 115, 123, 127, 131

and up
2 Added C33 (4-200), R92 (4-475), C34 (4-188) and 114, 123, 127,
C35 (4-188) 131, and up
Changed values: R84 (4-440) was 4.87 k , 1%; 115, 123, 127,
R85 (4-250) was 2.61 k , 1%; R15 (4-400) was 82 k , 5%; 131 and up
3 C3 (4-187) was 0.01 mF; R31 (4-450) was 1 k , 1%;
R30 (4-430) was 1.74 k , 1%; R18 (4-425) was 33.2  ,
1%; R28 (4-110) was select in test.

Page 2014
24-31-04 May 25/12
4-254

Page 2015/2016
24-31-04 May 25/12
4-254
BLANK
THIS PAGE
INTENTIONALLY
24-31-04
Page 2017
May 25/12
4-254
REVISION SERIAL NO.

None Remove incorrect revision callouts
3 4 5

4-254-03/-04 Battery Charger Schematic/Wiring Diagram
Page 2018
24-31-04 May 25/12
4-254

4-254-03/-04 Battery Charger Schematic/Wiring Diagram
Page 2019/2020
24-31-04 May 25/12
4-254
BLANK
THIS PAGE
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4-254-03/-04 A3A2 Board Schematic Diagram
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4-254-03/-04 A3A2 Board Schematic Diagram
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4-254
DISASSEMBLY
1. General
A. Use standard industry practices for disassembly of this component. Additional instructions are
given below only when specific procedures are needed. Refer to the IPL illustration for detail part
and attaching hardware information.
NOTE: In the following paragraphs IPL figure and item identification numbers are shown between
parentheses to help clarify part identification. The format used is (IPL Figure Number -
Item Number). For example, battery charger top cover (1-5) refers to IPL Figure 1 Item
Number 5).
B. Disassemble the Battery Charger only to the extent necessary to repair the unit. Refer to the
Testing and Fault Isolation section for fault isolation procedures.
C. To facilitate reassembly, identify each electrical lead and terminal with marked tape or similar
device when the lead is removed.
D. To remove components bonded with epoxy, soften the epoxy with a heat gun and pry the
component from the mounting surface.
2. Specific Disassembly Procedures
A. Before any disassembly, remove the top cover (1-5) and the bottom cover (1-15).
B. To remove A3A1 (1-290) or A3A2 (1-285), disconnect connectors (1-186) and (4-25) from PCB’s.
Remove screws (1-30) from mounting strip (1-25). Remove screws (1-280) from rear ends of side
heat sinks (1-315) and (1-410) holding rear heat sink (1-305).
Disconnect black grounding wires from PCB’s to rear heat sink (1-305). Remove screws (1-288;
see IPL Figure 1, Sheet 5) attaching R90 and R91 (4-235) from A3A1 to rear heat sink.
To separate A3A1 from A3A2, remove the 12 screws (1-300) fastening circuit boards to rear heat
sink (1-305). On the bottom row of 5 screws, remove only the two outer screws and the one
center screw. Carefully separate A3A1 (1-290) from A3A2 (1-285) to avoid damage to the post/
socket connections.
C. To remove input assembly A1 (1-35) loosen front panel by removing eight screws (1-67) that
fasten front panel to both side heat sinks and four screws (1-54) that secure front panel to front of
input assembly (1-35).
Disconnect three green wires and one black grounding wire from A1L1 (2-30) terminals 1, 3, 5
and 7. Disconnect black grounding wire from input assembly chassis terminal to front panel (lug
1-195).
Remove wires from E1, E2, E4, E5 and E7 on bottom of input assembly. Remove four screws
(1-280) fastening right heat sink (1-315) to rear heat sink (1-305), one screw fastening heatshield
(1- 205) to right side, and eight screws (1-45/1-57) fastening right heat sink (1-315) to right side of
A1 input assembly (1-35). Remove three screws holding left heat sink to bottom left side of A1
assembly (1-35).
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Disconnect wires from A1T1 terminals 7 and 8.
NOTE: Output filter (1-160) remains attached to the front panel (output terminal block). For
clarification, see IPL Figure 1 and IPL Figure 2.
Cut three cable ties on white wires at bottom of input assembly. Separate right heat sink from
remainder of Battery Charger and remove input assembly, moving it to the right to avoid the
terminal block and output filter assembly (1-160).
D. To remove output filter A5 (1-160), first remove input assembly (1-35) as above. Disconnect
output power lugs from A1L1 (1-430) and rectifier block A4A1 (1-470). Remove nuts (1-140 and
1-143; IPL Figure 1, Sheet 6) and attaching screws (1-106; IPL Figure 1, Sheet 6).
E. Removal of A1CR1 diode
To remove A1CR1 diode, the Input Assembly A1 (1-35) must be totally removed from the Battery
Charger. Refer to Illustrated Parts List IPL Figure 1 and IPL Figure 2 for parts detail and attaching
hardware information.
(1) Remove seven screws (1-10) and one screw (1-11) from Battery Charger Top Cover (1-5),
and set Top Cover aside.
(2) Remove seven screws (1-20) and one screw (1-21) from battery Charger Bottom Cover
(1-15), and set Bottom cover aside.
(3) Remove four screw (1-67) and four washers (1-68) that hold the Front Panel (1-65) to the
Right Side Heat Sink (1-310).
(4) Remove two screws (2-15) and two washers (2-20) from A1 Capacitor Shield (2-10).
(5) Remove four screw (two each 1-50 and two each 1-54) and four washers (1-55) that hold
the Front Panel to the front of the A1A1 Capacitor Assembly (2-115) of the Input Assembly
A1 (1-35).
(6) Identify and tag three green wires and two black grounding wires attached to Inductor A1L1
(2-30) terminals 1, 3, 5 and 7.
(7) Disconnect three green wires (terminal lugs) and two black grounding wires (terminal lugs)
from Inductor A1L1 (2-30) terminals 1, 3, 5 and 7.
(8) Disconnect two black grounding wires (terminal lugs) from the chassis ground Terminal Post
located on the back side of the Front Panel (1-65) above Connector J1 (1-189). One black
wire goes to the Input Assembly A1 (1-35) chassis, the second black wire goes to Connector
J1 (1-189).
NOTE: Figure 3001 shows wiring connections on the Input Assembly A1 (1-35).
(9) Identify and tag wires (terminal lugs) to Circuit Assembly A1A2 (2-135) terminal posts E1,
E2, E4, E5 and E7. The terminal posts are on the Circuit Assembly A1A2 located on the
bottom side of Input Assembly A1 (1-35).
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(10) Disconnect wires (terminal lugs) to Circuit Assembly A1A2 (2-135) terminal posts E2, E4, E5
and E7.
NOTE: Do not remove wire ties that hold wire harness at the A1A2 terminals.
(11) Remove four screws (1-280) and four washers (1-275) that hold Right Heat Sink (1-310) to
Rear Heat Sink (1-270).
(12) Remove one screw (1-206) and one washer (1-209) that hold Heatshield (1-205) to Right
Heat Sink (1-310).
(13) Remove seven screws (1-45) and seven washers (1-40) and one screw (1-57) and one
washer (1-40) that hold Right Heat Sink (1-310) to right side of Input Assembly A1 (1-35).
(14) Remove three screws (1-45) and three washers (1-40) that hold Left Heat Sink (1-405) to
bottom left side of Input Assembly A1 (1-35).
NOTE: The Output Filter (1-160) remains attached to the Front Panel Output Terminal
Block (1-105).
(15) Separate Right Heat Sink (1-310) from remainder of Battery Charger.
(16) Remove Input Assembly (1-35), moving it to the right to avoid the Terminal Block (1-105)
and Output Filter (1-160).
F. Removal of A1CR1
(1) Identify and tag the five wires soldered to the A1CR1 terminals.
(2) Unsolder and disconnect the five wires attached to the A1CR1 terminals.
(3) Remove two nuts (2-48), two washers (2-47) and two screws (2-46) that hold A1CR1 to the
Input Assembly A1 (2-5).
(4) Remove A1CR1 from the chassis (2-5).
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E1 E3 E4
A1A2
E2
LK #16 BLK #16 #16 RED

6B OR
#1 N
L2/L4
CR1
#16 3 2
- YEL #16
BR
L3 N
+
4 1
RN
D
N
RE
BR
6G
#16
#16
#1
T1 8
CR2
CR6 CR4
CR3
#22
BRN
CR7
CR5
1 (3)
E1
2
7
E2
C1
3
E3 #16 C2
4
GRN
C3
5
#16 BRN
6
L1
#16 RED 7
#18
#16 BLK BLK
4-254_R0011_EX-FIG 301
Figure 3001
Input Assembly A1, Detail of A1CR1 (part of 4-254301)
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CLEANING
1. General
This section contains instructions to clean the unit after disassembly or repair. Parts having the same
cleaning procedures are grouped under common headings. No special tools are required. Table 4001
gives the necessary materials. Equivalent replacements can be used for the items.
Table 4001
Cleaning Materials
MATERIAL SPECIFICATION USAGE
Low-lint Cloth - Dry parts after cleaning
Stoddard Solvent MIL-PRF-680, Type II Metallic surfaces
Isopropyl Alcohol Fed Spec TT-I-735 Clean connector contacts, electrical

components and metal surfaces
Soft bristled nonmetal brush - General cleaning; clean connector and

contacts
Low pressure compressed air - Clean and dry disassembled parts
WARNING: SOLVENTS USED TO CLEAN THE UNIT ARE POISONOUS. PREVENT SKIN CONTACT
WITH SOLVENTS; DO NOT BREATHE SOLVENT FUMES. USE APPROVED
RESPIRATORY PROTECTION. DO NOT LET SOLVENTS OR SOLVENT FUMES TOUCH

IGNITION SOURCES.
2. Cleaning Procedure
CAUTION: WHEN HANDLING CARDS AND IC’S, BE SURE TO FOLLOW THE PRECAUTIONS FOR
STATIC-FREE HANDLING OF CMOS COMPONENTS.
A. Procedure
(1) Remove excess solder from all solder joints and from chassis.
(2) Brush all surfaces, parts, and wiring by using a nonmetallic, soft-bristled brush.
WARNING: SOLVENTS USED TO CLEAN THE UNIT ARE POISONOUS. PREVENT SKIN
CONTACT WITH SOLVENTS; DO NOT BREATHE SOLVENT FUMES. USE
APPROVED RESPIRATORY PROTECTION. DO NOT LET SOLVENTS OR
SOLVENT FUMES TOUCH IGNITION SOURCES.
(3) Wipe finished surfaces with a clean cloth dampened with standard solvent or alcohol. Dry
with a clean, low-lint cloth.
WARNING: WEAR SAFETY GOGGLES WHEN USING LOW-PRESSURE COMPRESSED AIR.
(4) Clean printed wiring cards and electrical components with a nonmetal brush and alcohol,
then dry with compressed air.
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Page 4002
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4-254
REPAIR
1. General
A. General Practices
(1) Replace parts determined to be defective by test and fault isolation.
(2) The procedures given in IPC-7711B/7721B or later can be used instead of or in addition to
the procedures for any repairs to the CCAs.
(3) Follow standard industry practice in making repairs; evidence of incorrect repair procedures
may void ELDEC equipment warranties.
(4) Refer to the Illustrated Parts List for detailed parts and attaching hardware layout. Any
additional details needed for part removal or installation is provided in the Disassembly and
Assembly sections.
(5) When defective parts must be replaced, use only those parts specified in the parts list.
(6) Mount new or replaced parts in the same position formerly occupied by the faulty parts.
Fasten all mountings securely. Torque nuts, as required, under Fits and Clearances.
B. General Procedures
(1) Tag all leads before disconnecting them from terminals. Use small tags or short pieces of
adhesive tape. Identify each lead so that it may be connected to the proper terminal during
reassembly.
(2) Clean all connections thoroughly before soldering. Use standard soldering techniques for
electronic equipment when installing replacement parts. Use Sn63Pb37 solder with resin
core unless otherwise specified.
CAUTION: ACID SOLDER FLUX CAUSES SEVERE CORROSIVE DAMAGE TO ELECTRICAL

COMPONENTS. USE OF SOLDER WITH ACID FLUX VOIDS ALL ELDEC
EQUIPMENT WARRANTIES.
(3) After the soldering operation, the area of the joint shall be cleaned thoroughly using
isopropyl alcohol. Solvent containing dissolved flux shall not be allowed to penetrate
components such as connector sockets, because resin flux is an insulator.
(4) Removal of bonded components has been covered in the Disassembly section.
To bond replacement components, use two-part epoxy. Cure at room temperature for 24
hours or at 150 °F (65 °C) for 2 hours.
(5) Ensure all diode block, output inductor and output terminal block connections are correctly
tightened. See the Fits and Clearances section.
(6) Torque rectifiers (1-495) (see FITS AND CLEARANCES) before soldering.
NOTE: When making solder connections to rectifiers A4A1CR1 and CR2, use High-Temp
solder Sn96.3Ag3.7 or equivalent. Use needle-nose pliers or an appropriate heat
sink device between the solder connection and the diode. Avoid prolonged heating
of rectifiers.
Page 6001
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2. Materials and Tools
A. Materials
Table 6001 gives the necessary consumable materials to repair the Battery Charger.
NOTE: Equivalent alternatives can be used.

Materials Necessary for Repair
SPECIFICATION/
NOMENCLATURE SOURCE (VENDOR) USE
PART NO.
Isopropyl Alcohol TT-I-735 Commercial Clean connector

contacts, CCA, and
electrical components
Insulating Compound PC12-007 or Dexter Corporation Repair CCA

PC12-007M (V12405)
Copper Pad Commercial, 0.002 inch Commercial Repair pads and traces
(0.051 mm) thick, coated
with tin
Conformal Coating Amber Humiseal, 1A20 Chase Corporation CCA coating

(V99109)
Solder Sn63Pb37 (J-STD-006) Commercial Component leads and

with ROL0 or ROL1 flux wire
(J-STD-004)
Solder, High-Temp Sn96.3Ag3.7 (J-STD-006) Commercial For high temperature

with ROL0 or ROL1 flux soldering. Use only
(J-STD-004) where specified.
Solder Wick Braid with ROL0 or ROL1 Commercial Remove Solder

flux
Adhesive, Epoxy, 2216 B/A, Color: Gray 3M Company. (V1A9T3) Bond components and
Two-Part screws
Powder, Colloidal Sil- Cab-O-Sil, M-5 Cabot Corporation Bond components

ica (V80798)
Wire, 24 AWG LW_0.51_C-32-N Commercial Jumper connections
Wire, 18 AWG M22759/11-18-9, White Commercial Wire replacement
Wire, 16 AWG LW_1.27_C-32-N Commercial Wire replacement
Wire, 22 AWG M22759/11-22-3, Orange Commercial Wire replacement
Wire, 22 AWG M22759/11-22-4, Yellow Commercial Wire replacement
Wire, 14 AWG M22759/11-14-9, White Commercial Wire replacement
Page 6002
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4-254

Materials Necessary for Repair
SPECIFICATION/
NOMENCLATURE SOURCE (VENDOR) USE
PART NO.
Sleeving, 22 AWG TFE, 0.012 Wall, White Commercial Component lead

insulation
Sleeving, 24 AWG TFE, 0.012 Wall, White Commercial Component lead

insulation
Sleeving, 20 AWG TFE, 0.034 ID, Natural Commercial Component lead

insulation
Sleeving, 16 AWG TFE, 0.053 ID, Natural Commercial Jumper lead insulation
Polyimide Tape 2345-1, 2.250 Width, Oak-Mitsui (V4M1M7) Wind the Capacitors C1
0.001 inch Thick and C2
Lacing Tape 0.010 X 0.050 inch (0.254 Commercial Attach the Capacitors
X 1.27 mm) C1 and C2 together
Natural (Mil Spec
A-A-52081, #5)
Plastic Strap MS3367-4-9 Commercial Attach wires together

B. Tools Necessary for Repair
Table 6002 gives the tools and equipment necessary for repair.
NOTE: Equivalent alternatives can be used.
Table 6002
Tools Necessary for Repair
SPECIFICATION/
NOMENCLATURE SOURCE (CAGE) USE
PART NO.
Abrading Tool Dremel Moto-Flex, Model Dremel Mfg. (V18531) Repair PWB
332-5
Hot Air Dryer 220 °F (104 °C) Commercial Soften epoxy bond
Oven 140 °F (60 °C) Commercial Repair of CCA and

conformal coat
Insertion Tool MS24256A20, 20 gauge Commercial Connector Repair
Insertion Tool MS24256A16, 16 gauge Commercial Connector Repair
Crimping Tool MS22520/1-01 Commercial Connector Repair
Removal Tool MS24256R20, 20 gauge Commercial Connector Repair
Removal Tool MS24256R16, 16 gauge Commercial Connector Repair
Page 6003
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3. Special MOS Device Handling Procedures
A. The A3A1 (IPL Figure 3) circuit board contains MOS devices, reference designators U4, U5, U6,
U7 and U8.
B. MOS devices require special handling to avoid damage due to electrical charge. Use the following
procedures when handling, removing, storing, transporting, installing or testing MOS devices:
(1) Wear anti-static clothing, such as cotton. Do not wear nylon smocks or gloves.
(2) Keep all leads of uninstalled devices shorted together, whenever possible, when handling,
transporting, or storing devices.
(3) Avoid using equipment that does not permit grounding MOS device leads during handling.
(4) Place a CAUTION statement (similar to the one below) on all shipping/storage containers
that contain MOS devices and on all work and handling documents involving MOS devices.
CAUTION: MOS DEVICE - SPECIAL HANDLING REQUIRED.
(5) Use conductive trays, graphite foam, conductive rubber containers, or other suitable
conductive medium. Insert the leads through the conductive medium.Do not place MOS
devices in conventional plastic foam, polystyrene trays, or poly bag without ensuring that the
pins of the devices are electrically shorted together.
(6) At each work station handling MOS devices install a conductive strip or plate connected to
ground potential. Ground all soldering equipment.
Touch the grounded conductive surface before touching the MOS device.
NOTE: For optimum protection of devices, attach a conductive strip around the wrist and
bond the strip to the grounded conductive surface.
(7) Ensure that voltage sources to test or other circuits are turned off before inserting or
removing devices.
(8) Consider the circuit board contacts as extensions of MOS device leads until installed in the
Battery Charger. Ground the connector edge of the board with conductive tape when the
board is not installed in the charger - especially when mounting MOS devices.
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4. CCA Repair Procedures
CAUTION: FOLLOW STANDARD ELECTRO-STATIC DISCHARGE (ESD) PRACTICES AND

PRECAUTIONS WHEN YOU HANDLE CCAS. CCAS CONTAIN ESD SENSITIVE
COMPONENTS.
NOTE: Do not repair sealed or potted components such as amplifiers and transformers; replace the
component.
A. CCA Laminate Repair
(1) Remove damaged laminate with a low speed, high torque flexible abrading tool.
(2) Soak the damaged area with isopropyl alcohol. The soaked area must be equally
translucent.
NOTE: If an area looks milky, defective laminate must be removed with the abrading tool.
(3) Clean the area of repair (Refer to CLEANING).
(4) Fill damaged area with insulating compound. Work the compound as necessary to fill voids
and remove bubbles.
NOTE: Do not get insulating compound on the circuit traces and pads.
(5) Cure the compound in an oven at +150 °F (+65 °C) for 4 hours after the insulating
compound and two-part epoxy adhesive are applied.
NOTE: Insulating compound that extends above the plane of the CCA must be made level
with an abrading tool.
NOTE: Be careful to prevent damage to adjacent circuit traces, pads, or components.
B. Lifted Circuit Pads or Traces Repair
(1) If necessary, remove conformal coating. (Refer to paragraph 4.G. Conformal Coating
Removal.)
(2) If necessary, remove the components from area of repair. (Refer to paragraph 5.A. Plated
Through-Hole Component Removal.)
(4) Apply two-part epoxy adhesive in the void between the lifted pad or trace, and the base
laminate. Press the pad or trace down tightly against the base laminate, let more epoxy flow
above and around the repair area. (Refer to paragraph 4. F. Epoxy Bond Replacement.)
NOTE: Make sure the two-part epoxy adhesive is kept away from a surface that has solder.
(5) Install and apply solder to the components removed from the area of repair. (Refer to
paragraph 5.B. Plated Through-Hole Component Replacement.)
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(6) Apply conformal coating to the area of repair. (Refer to paragraph 4.H. Conformal Coating
Replacement.)
C. Missing Pad Repair (Connected to Trace)
(2) Replace missing pads with a commercially available pre-tinned copper pads and traces, of
equal or more width than the proximity card trace. If necessary, bond the new pad or trace to
the laminate with two-part adhesive epoxy. (Refer to paragraph 4.F. Epoxy Bond
Replacement.)
NOTE: The trace must be sufficient length to overlap the remaining trace a minimum of
0.125 inch (3.175 mm).
(3) Use an abrading tool to make the overlap area of the trace rough.
(5) Set the replacement pad with trace on component lead.
(6) Apply solder to the replacement trace to remaining trace in the prepared overlap area and
apply solder to the component lead in the pad.

(8) Apply insulating compound around the repaired area of the pad. Work the compound as
necessary to fill voids and remove bubbles. Remove compound that is more than
necessary.
NOTE: Do not let the insulating compound on circuit traces and pads.
(9) Cure compound in oven at +150 °F (+65 °C) for 4 hours.
NOTE: Insulating compound in the area of repair that extends above the plane of the board
must be made level with an abrading tool.
D. Missing Pad Repair (Not Connected to Trace)
(2) Replace missing pads with a commercially available pre-tinned copper foil. If necessary,
bond the new pad to the laminate with 2-part epoxy. (Refer to paragraph 4.F. Epoxy Bond
Replacement.)
(3) Use an abrading tool to make the area of the replacement pad rough.
(5) Set the replacement pad on the component lead.
(6) Apply solder to the replacement pad to the component lead.
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(8) Apply insulating compound around the repaired area of the pad. Work the compound as
necessary to fill voids and remove bubbles. Remove compound that is more than
necessary.
NOTE: Do not let the insulating compound set on circuit traces and pads.
(9) Cure compound in oven at +150 °F (+65 °C) for 4 hours.
NOTE: Compound in the area of repair that extends above the plane of the board must be
made level with an abrading tool.
E. Epoxy Bond Removal
CAUTION: DO NOT OVERHEAT NEARBY COMPONENTS.
(1) Remove epoxy bonded components with a hot air dryer. Heat the epoxy until it is sufficiently
soft to remove the component.
(2) Let the proximity card cool to ambient temperature.
F. Epoxy Bond Replacement

(1) Use the vendor’s instructions to mix two-part epoxy adhesive. If necessary, use no more
than 2% colloidal silica powder to increase the viscosity of the two-part adhesive.
(2) Bond components with the two-part epoxy adhesive compound. Use epoxy below the
component or in a tack bond or fillet-bond, as required.
NOTE: Use small drops of two-part epoxy adhesive at the corners or the sides of the
components where a tack bond is necessary.
NOTE: Use a continuous bead of two-part epoxy adhesive for components where a fillet-
bond is necessary. Apply the epoxy along the edge of components that attach to a
heatsink or circuit board.
(3) Set the Proximity Card in a 150 °F (65 °C) oven and cure epoxy for two hours, or air dry at
ambient temperature 68 °F (20 °C) for 24 hours.
NOTE: Do the cure in the oven after all bonds are completed.
G. Conformal Coating Removal
(1) Remove conformal coating that is adjacent to the repair area. Use a desoldering tool to
remove the conformal coating.
(2) If a scraping tool is used to remove conformal coating, make sure that CCA traces, adjacent
components, and laminations are not damaged.
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H. Conformal Coating Replacement
NOTE: Conformal coating is applied after all components are replaced and bonded (if
necessary).
(1) Let card cool to ambient temperature.
(2) Apply conformal coating above the area of repair. New coating must extend a minimum of
0.030 inch (0.762 mm) adjacent to the area of repair. Nominal thickness must be 0.01 to
0.03 inches (0.254 to 0.762 mm) on flat surfaces.
NOTE: Do not apply conformal coating to connectors or conductive surfaces that attach to
terminals, lugs, and posts, or to flat areas where components will be installed.
(3) Air cure the conformal coating at ambient temperature, +68 °F to +86 °F (+20 °C to +30 °C),
with a relative humidity of 30 to 70% for 3 hours minimum.
5. Component Repair Procedures
A. Plated Through-Hole Component Removal
CAUTION: LIMIT SOLDER OPERATION TO LESS THAN 5 SECONDS. LONGER PERIODS

CAN DAMAGE CARD OR COMPONENT DUE TO FLUX CARBONIZATION. USE A
30- TO 50- WATT SOLDERING PENCIL AND HEATSINKS TO PREVENT DAMAGE

TO HEAT-SENSITIVE COMPONENTS.

COMPONENTS.
(1) Remove the conformal coating in the area of repair. (Refer to paragraph 4.G. Conformal
Coating Removal.)
(2) If necessary, remove epoxy bond from the component. (Refer to paragraph 4.E. Epoxy
Bond Removal.)
(3) After solder removal, remove residual solder, if necessary, with solder wick.
(4) Remove the defective component.
B. Plated Through-Hole Component Replacement
CAUTION: ACIDIC SOLDER FLUX CAUSES SEVERE CORROSIVE DAMAGE TO

ELECTRICAL COMPONENTS. USE OF SOLDER WITH ACIDIC FLUX VOIDS ALL
EQUIPMENT WARRANTIES. SOLDER WITH ENERGIZED ROSIN CORE
SOLDER.
Page 6008
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(1) Install and apply solder to the replacement components on the CCA. Make sure the
component height limits are as given: 0.625 inch (15.875 mm) measured from the
component-side surface. Cut the leads on the circuit side to 0.150 inch (3.810 mm)
maximum, flush minimum.
NOTE: All small axial-lead components must have 0.500 inch (12.700 mm) clearance
between leads.
(2) Replace the epoxy-mounted component. (Refer to paragraph 4.F. Epoxy Bond
Replacement.)
(3) Let CCA cool to ambient temperature.
(4) Apply conformal coating to the repaired area. (Refer to paragraph 4.H. Conformal Coating
Replacement.)

COMPONENTS.
6. A5A1 Filter Cap Assembly
Refer to IPL Figure 1 (Sheet 6).
A. C1, C2, and C3 Capacitor Replacement

(1) Remove the damaged capacitor C1 (165) or C2 and C3 (170) from the Filter Cap Assembly
(160).
(2) Install the replacement capacitor on the Filter Cap Assembly (160).
(3) Bond capacitor C1 or C3 to the Filter Cap Assembly (160) with two-part epoxy.
(4) If necessary, bond the capacitor C2 to the capacitor C1 with two-part adhesive.
(5) Clean the area of repair.
(6) Apply conformal coating to the area of repair.
7. A4 Left Heat Sink Assembly
A. C1 and C2 Capacitor Replacement
(1) Remove the damaged capacitor C1 or C2 (411) from the left heat sink (410).
(2) Install and solder the replacement capacitor to the left heat sink (410).
(3) Bond the capacitor to the left heat sink (410) with two-part epoxy.
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8. A4A1 Output Diode Assembly
A. C3 Capacitor Replacement
(1) Remove the damaged capacitor C3 (501) from the rectifier mounting block (490).
(2) Install and solder the replacement capacitor to the rectifier mounting block (490).
(3) Bond the capacitor to the rectifier mounting block (490) with two-part epoxy.
9. Snubber Output Assembly
(1) Remove the damaged capacitor C1 or C2 (525) from the Snubber Output Assembly (505).
(2) Install and solder the replacement capacitor to the Snubber Output Assembly (505).
(3) Bond the capacitor to the Snubber Output Assembly (505) with two-part epoxy.
B. R1 and R2 Resistor Replacement
(1) Remove the damaged resistor R1 or R2 (530) from the Snubber Output Assembly (505).
(2) Install and solder the replacement resistor to the Snubber Output Assembly (505).
(3) Bond the resistor to the Snubber Output Assembly (505) with two-part epoxy
10. A1 Input Assembly
Refer to IPL Figure 2.
(1) Remove the damaged capacitor C1, C2, or C3 (175) from the inductor L1 (30).
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(2) Sleeve the replacement capacitor leads with 22 AWG TFE sleeving.
(3) Install and solder the replacement capacitor to the inductor L1 (30).
(4) Bond the capacitor to the inductor L1 (30) with two-part epoxy.
11. A1A2 Circuit Card Assembly
(1) Remove the damaged capacitor C1 or C2 (170) from the CCA.
(2) Install and solder the replacement capacitor to the CCA.
(3) Bond the capacitor to the CCA with two-part epoxy.
NOTE: The component leads and shaded areas shown in Figure 6001 must be free from
epoxy.
(4) Attach the capacitors C1 and C2 tightly together to the CCA with the lacing tape.
(5) Apply polyimide tape to the capacitors C1 and C2 so that it extends 0.03/0.20 inch
(0.76/5.08 mm) beyond the ends and a minimum of 0.10 inch (2.54 mm) on the down sides
below the centre line. Refer to Figure 6001.
NOTE: The component surfaces of the capacitors C1 and C2 and the bonding material
must be kept within the maximum dimension 2.05 inch (52.07 mm) as shown in
Figure 6001.
B. C3 thru C8 Capacitor Replacement
(1) Remove the damaged capacitor C3, C4, C5, C6, C7, or C8 (165) from the CCA.
NOTE: The component leads and shaded areas in Figure 6001 must be free from epoxy.
Page 6011
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Figure 6001
C1 thru C8 Capacitor Replacement (A1A2)
12. A1A1 Capacitor Assembly
Refer to IPL Figure 2 and Figure 6002.
(1) Remove the damaged capacitor C1, C2, or C3 (130) from the capacitor mounting bracket
(128).
(2) Install and solder the replacement capacitor to the capacitor mounting bracket (128).
(3) Bond the capacitor to the capacitor mounting bracket (128) with two-part epoxy.
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.
Figure 6002
C1, C2, and C3 Capacitor Replacement (A1A1)
A. R4 Resistor Replacement
(1) Remove the damaged resistor R4 (220) from the CCA.
(2) Install and solder the replacement resistor to the CCA.
(3) Bond the resistor to the CCA with two-part epoxy.
NOTE: The heat sink side of the resistor R4 must be free from adhesive.
B. C14 Capacitor Replacement
(1) Remove the damaged capacitor C14 (190) from the CCA.
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C. C29 and C30 Capacitor Replacement (4-254253-01, -02, -03, -04, 4-254453-02, and -04 only)
(1) Remove the damaged capacitor C29 (217) or C30 (215) from the CCA.
D. C31 and C32 Capacitor Replacement (4-254253-02, 4-254453-02, and -04 only)
(1) Remove the damaged capacitor C31 (216) or C32 (430) from the CCA.
E. R87 Resistor Replacement (4-254353-03, -04, 4-254453-03, -04, and 4-254553-02 only)
(2) Sleeve the replacement resistor leads with 0.034 ID TFE sleeving.
F. J1 Connector Replacement (4-254353-01, -02, -03, -04, 4-254453-01, -03, 4-254553-01, and -02
only)
(1) Remove the two screws (26 and 31), two lock washers (35), two flat washers (40), and
insulator (42) from the J1 connector (25).
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(2) Remove the damaged J1 connector (25) from the CCA.
(3) Install the replacement connector on the CCA with the two screws (26 and 31), two lock
washers (35), two flat washers (40), and insulator (42).
(4) Solder the connector to the CCA.
G. J1 Connector Replacement (4-254253-01, -02, -03, -04, 4-254453-02, and -04 only)
(1) Remove the two screws (26 and 31), three lock washers (35), four flat washers (40), lug
(28), and nut (27) from the J1 connector (25).
(2) Remove the conformal coating that covers the J1 connector from the CCA.
(3) Install the replacement connector on the CCA with the two screws (26 and 31), three lock
washers (35), four flat washers (40), lug (28), and nut (27).

H. Q2 thru Q8, Q10, and Q11 Transistor Replacement
(1) Remove the damaged transistor Q2, Q3, Q7, Q8, Q10, and Q11 (150) or Q4, Q5, and Q6
(155) and pad (15) from the CCA.
(2) Install and solder the replacement transistor and pad to the CCA.
I. U1 thru U8 Microcircuit Replacement (except 4-254553-01 and -02)
(1) Remove the damaged microcircuit U1 and U2 (120), or U3 (125), U4 (130), U5 (135), U6
and U7 (140), or U8 (145) and insulator (20) from the CCA.
(2) Install and solder the replacement microcircuit and insulator to the CCA
J. R1 Resistor Replacement
(1) Remove the damaged resistor R1 (225) and insulator from the CCA.
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(2) Install and solder the replacement resistor and insulator to the CCA.
NOTE: The heat sink side of the resistor R4 must be free from epoxy.
A. C25 Capacitor Replacement
(3) Tack bond the capacitor to the CCA with two-part epoxy.

B. C31 Capacitor Replacement (4-254255-01, -02, and 4-254655-03 only)
C. R48, R51, R54, R64, and R67 Resistor Replacement
(1) Remove the damaged resistor R48 (265), R51 (255), R54 (260), R64 (255) and insulator
(45) from the CCA.
(2) Tack bond the replacement resistor to the insulator (45) with two-part epoxy.
(3) Fillet bond the insulator (45) to the CCA with two-part epoxy.
NOTE: The bonding fillet must be a minimum of 50% of the outside portion of the insulator
(45).
(4) Apply solder to the component leads.
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D. C33 Capacitor Replacement (4-254255-02 only)
E. R92 Resistor Replacement (4-254255-02 only)
(2) Sleeve the replacement resistor leads with 22 AWG TFE sleeving.
F. C10 Capacitor Replacement (4-254455-01 and 4-254655-02 only)
(4) Bond the capacitor to the spacer with two-part epoxy.
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Figure 6003
C10 Capacitor Replacement
G. R94 Resistor Replacement (4-254655-01, -02, and -03 only)

Refer to IPL Figure 4 (Sheet 9 and 12).
(2) Sleeve the replacement resistor leads with 24 AWG TFE sleeving.
(4) Bond the resistor to the CCA with two-part adhesive epoxy.
H. C39 Capacitor Replacement (4-254655-01, -02, and -03 only)
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I. Res, Cap, Diode Network Replacement (4-254655-01, -02, and -03 only)
(1) Remove the damaged res-cap-diode network (500) from the solder side of the CCA.
(2) Sleeve the replacement res-cap-diode network leads and 24 AWG jumper wire with 24
AWG TFE sleeving.
(3) Install and solder the replacement res-cap-diode network to the CCA.
(4) Bond the res-cap-diode network to the CCA with two-part epoxy.
(5) Bond the sleeved 24 AWG jumper wire to the CCA with two-part epoxy.
J. C37 and C38 Capacitor Replacement (4-254655-02 and -03 only)

K. C34 and C35 Capacitor Replacement (4-254655-03 only)
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L. J1 Connector Replacement (4-254455-01, 4-254555-01, 4-254655-01, -02, and 4-254755-01

only)
(1) Remove the two screws (26 and 30), two lock washers (35), two flat washers (40), and
insulating washer (42) from the J1 connector (25).
(2) Remove the conformal coating that covers the J1 connector (25) pin pads, on the circuit side
of the CCA.
washers (35), two flat washers (40), and insulating washer (42).
M. J1 Connector Replacement (4-254255-01, -02, and 4-254655-03 only)
(1) Remove the two screws (26 and 31), two lock washers (35), two flat washers (40), lug (28),
and nut (27) from the J1 connector (25).
(2) Remove the conformal coating that covers the J1 connector (25) pin pads, on the circuit side
of the CCA.
washers (35), two flat washers (40), lug (28), and nut (27).
N. Q1 thru Q6, Q8, Q12, and Q17 thru Q20 Transistor Replacement
(1) Remove the damaged transistor Q1 (115), Q2 (100), Q3 thru Q5 (115), Q6, Q8, Q12, Q17,
and Q18 (100), or Q19 and Q20 (120)and the transistor and pad (10) from the CCA.
(2) Install and solder the replacement transistor and pad (10) to the CCA.
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O. Q7, Q9 thru Q11, and Q13 thru Q16 Transistor Replacement
(1) Remove the damaged transistor Q7 and Q9 (95), Q10 (85), Q11 and Q13 (95), Q14 (85), or
Q15 and Q16 (90) and pad (15) from the CCA.
(2) Install and solder the replacement transistor and pad (15) to the CCA.
P. U1, U3 thru U8 Microcircuit Replacement (except 4-254755-01)
(1) Remove the damaged microcircuit U1 (60), U3 and U5 (65), U4 (70), U6 (75), or U7 and U8
(80) and insulator (20) from the CCA.
(2) Install and solder the replacement microcircuit and insulator (20) to the CCA.
Q. R49 and R62 Resistor Replacement
(1) Remove the damaged resistor R49 or R62 (240) and insulator (242) from the CCA.
(2) Install and solder the replacement resistor and insulator (242) to the CCA.
(2) Install and solder the replacement capacitor to the CCA
(3) Bond the capacitor to the CCA with two-part epoxy
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B. T1 and T4 Transformer Replacement
(1) Remove the damaged transformer T1 or T4 (40) from the CCA.
(2) Install and solder the replacement transformer to the CCA.
(3) Bond the transformer to the CCA with two-part epoxy.
C. Jumper Wire Replacement
(1) Remove the damaged jumper wire from the CCA.
(2) Install and solder the replacement wire as given in Table 6003.
(3) Tack bond the wires to the CCA with two-part epoxy.
(4) If necessary, attach the wires together with the plastic strap and lacing tape.

Table 6003
Wire Connection Details
4-254411-01, -02 and 4-254511-01 4-254311-01
FROM TO COLOR FROM TO COLOR
P1-11 E2 ORG 22 AWG P1-11 E2 ORG

P1-1 E9 YEL 22 AWG P1-1 E9 YEL
P1-12 T2-1 BRN P1-12 T2-1 BRN
P1-3 T2-2 RED P1-3 T2-2 RED
P1-5 T2-5 GRN P1-5 T2-10, 5 GRN
P1-7 T2-7 BLU P1-7 T2-6, 7 BLU
P1-8 T2-8 GRY P1-8 T2-8 GRY
P1-4 T2-9 WHT P1-4 T2-9 WHT
P1-13 T3-2 RED P1-13 T3-2 RED
P1-14 T3-1 BRN P1-14 T3-1 BRN
P1-19 T3-9 WHT P1-19 T3-9 WHT
Page 6022
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Table 6003
Wire Connection Details
4-254411-01, -02 and 4-254511-01 4-254311-01
FROM TO COLOR FROM TO COLOR
P1-20 T3-5 GRN P1-20 T3-10, 5 GRN

P1-9 T3-7 BLU P1-9 T3-6, 7 BLU
P1-10 T3-8 GRY P1-10 T3-8 GRY
E251 T2-3 ORN E25 T2-3 ORN
E241 T2-4 YEL E24 T2-4 YEL
NC2 T2-3 ORN E24 T2-11 WHT/BRN
T2-42 E28 YEL E22 T2-12 WHT/RED
E24 T2-11 WHT/BRN E24 T2-13 WHT/ORN

E3 T2-12 WHT/RED E22 T2-14 WHT/YEL
E24 T2-13 WHT/ORN E19 T3-3 ORN
E3 T2-14 WHT/YEL E18 T3-4 YEL
E191 T3-3 ORN E18 T3-11 WHT/BRN

E181 T3-4 YEL E27 T3-12 WHT/RED
NC2 T3-3 ORN E18 T3-13 WHT/ORN
T3-42 E29 YEL E27 T3-14 WHT/YEL
E18 T3-11 WHT/BRN E27 E16 RED

E27 T3-12 WHT/RED E26 E1 RED
E18 T3-13 WHT/ORN E22 E3 GRN
E27 T3-14 WHT/YEL E20 E3 BUS
E27 E16 BUS 16 AWG E24 CR2 BUS
E26 E1 BUS 16 AWG R2 E18 BUS
E201 E3 WHT 18 AWG
E202 E3 WHT 14 AWG
1. 4-254411-01 only.
2. 4-254411-02 and 4-254511-01 only.
Page 6023
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Wire Replacement
24-31-04
Page 6024
May 25/12
4-254

Wire Replacement
D. P1 Connector Replacement
(1) Remove the damaged connector P1 (55) from the CCA.
(2) Install and solder the replacement connector to the CCA.
(3) Install and solder the replacement wires as given in Table 6003.
E. T2 and T3 Transformer Replacement
(1) Remove the damaged transformer T2 or T3 (35) from the CCA.
(2) Install and solder the replacement transformer to the CCA.
(3) Bond the transformer to the CCA with two-part epoxy.
(4) If necessary, Install and solder replacement wires as given in Table 6003.
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BLANK
THIS PAGE
INTENTIONALLY
24-31-04
Page 6026
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ASSEMBLY
1. General
Use standard industry practices to assemble the Battery Charger. Refer to the Illustrated Parts List
(IPL) for assembly and parts data and illustrations. The assembly procedures in this section give
special instructions for component installation.
2. Recommended Materials, Tools, fixtures and Equipment
Table 7001 is a list of recommended materials. No special tools that are necessary to assemble the
Battery Charger.
NOTE: Equivalent substitutes may be used.

Materials Necessary for Assembly
PART NUMBER/ SOURCE

ITEM USE
SPECIFICATION (CAGE)
The material that follows is used during the A5, A2Q1, A2Q2, A3A1Q1, and A3A1U9 installation (instruc-
tions are given in paragraph 3. and paragraph 4.):
Sealant, MIL-S-46163, Type 2, Commercial Attach screws

Thread Locking Grade-N
Adhesive, Silicon RTV 3145-Clear Dow Corning Corp. Attach screws

(V71984)
Encapsulant, Silicone Circalock 6709 with catalyst Lord Corp. (V29966) Resistors R1 and R2
6731, Thermally conduc- (1-530) installation
tive RTV
Adhesive, Epoxy, 2216 B/A, Color: Gray 3M Company. Capacitors C1 and

Two-Part (V1A9T3) C2 (1-411) installa-
tion
Tubing, Heat-shrinkable Thermofit RNF-100, Type Tyco Electronics to cover white wires
1, Black, 0.125 ID, Corp. (V06090) 20 AWG
Tiedown straps MS3367-4-9, Adjustable, Commercial Attach wires

self-clinching plastic
The materials that follow are used during the A2A1 Circuit Card Assy installation when the 1-390B or
1-390C part is the replacement for the 1-390 or 1-390A part:
Wire, 22 AWG M22759/11-22-3, 8 inches Commercial Wire Replacement

(20.3 cm), Insulated,
Orange
Wire, 22 AWG M22759/11-22-4, 12 inches Commercial Wire Replacement

(30.5 cm), Insulated, Yellow
Page 7001
24-31-04 May 25/12
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Materials Necessary for Assembly
PART NUMBER/ SOURCE

ITEM USE
SPECIFICATION (CAGE)
Terminal splices (Qty 2) Not Specified Commercial 22 AWG wiring insu-

lation
Tubing, Heat-shrinkable, Thermofit RT-850, Tyco Electronics Terminal splices

Polyvinyl Kynar, tan, 0.125 ID Corp. (V06090) insulation
Solder Sn63Pb37 (J-STD-006) Commercial Component leads

with ROL0 or ROL1 flux and wire
(J-STD-004)
Solder, High-Temp Sn96.3Ag3.7 (J-STD-006) Commercial For high temperature

with ROL0 or ROL1 flux soldering. Use only
(J-STD-004) where specified.
3. Assembly Procedures
A. Make sure all component surfaces are clean and do not have unwanted particles. Make sure all
component surfaces have smooth edges. This will let these component surfaces make better
contact when they are installed.
NOTE: In the paragraphs that follow, the IPL figure and item numbers are shown in parentheses.
For example: (1-495) refers to IPL Figure 1 - item number 495, which are the rectifiers
(power diodes) CR1 and CR2.
B. (Refer to IPL Figure 1, Sheet 3.) To assemble the A4 Left Heat Sink Assembly (1-405), do the
procedures that follow as are necessary. To attach resistors R1 and R2 (1-415) to the left heat
sink (1-410), first apply silicone encapsulant (refer to paragraph 2., Materials) to the component
mounting surfaces. Attach resistors R1 and R2 (1-415) to the left heat sink (1-410) with screw
(1-420) and washer (1-425). Bond capacitors C1 and C2 (1-411) to the left heat sink (1-410) with
two-part epoxy. (Cure at room temperature for 24 hours or at 150 °F (65 °C) for 2 hours.) Install
the rectifiers (power diodes) CR1 and CR2 (1-495) into the rectifier mounting block (1-490) of the
A4A1 Output Diode Assembly (1-470). Torque the rectifiers to 25 to 30 lb-in (2.8 to 3.4 N-m).
Solder the wires from transformer T1 (1-544) and the wires from the snubber assembly (1-505)
resistors R1 and R2 (1-530) to rectifiers CR1 and CR2 (1-495).
CAUTION: BEFORE YOU INSTALL AN INSULATED COMPONENT, MAKE SURE ALL SURFACES
ARE CLEAN AND DO NOT HAVE UNWANTED PARTICLES. MAKE SURE ALL
SURFACES HAVE SMOOTH EDGES. ANY METAL FILING, HARD UNWANTED
PARTICLE, OR RAISED METAL EDGE ON A COMPONENT SURFACE CAN BREAK OR
PUT A HOLE THROUGH THE INSULATOR. THIS CAN CAUSE A SHORT-CIRCUIT
CONDITION THAT CAN DAMAGE THE BATTERY CHARGER.
To install the A4A1 Output Diode Assembly (1-470), put the insulator (1-465) on the left heat sink
(1-410) surface. Put the A4A1 Output Diode Assembly (1-470) on the insulator (1-465) and attach
it to the left heat sink (1-410) with washers (1-480), washers (1-476), and screws (1-475).
Page 7002
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After the A4A1 Output Diode Assembly is attached to the left heat sink, and before you connect
the wires to it, measure its insulation resistance. Measure the metal-to-metal resistance from the
A4A1 Output Diode Assembly to the left heat sink. The resistance must be > 1 M .
Attach the white wire with lug (1-196) and the white 10 AWG wires with lug (1-182) to the A4A1
Output Diode Assembly (1-470) with screw (1-606) and washer (1-607). [The large lug (1-182)
must make direct contact with the rectifier mounting block (1-490).] Torque screw (1-606) to
45 to 50 lb-in (5.1 to 5.7 N-m). Attach lug (1-584) to the left heat sink (1-410) with screw (1-585),
washer (1-590), washer (1-595), washer (1-600), and nut (1-605).
Attach the output inductor L1 (1-430) to the left heat sink (1-410) with washers (1-435) and screws
(1-440). Attach the input harness A6 (1-185) to the output inductor L1 (1-430) with clamp (1-406),
washer (1-408), and screw (1-407). Attach the black 10 AWG wires with lug from transformer T1
(1-544) to the output inductor L1 (1-430) with bolt (1-445), washers (1-450), washer (1-455), and
nut (1-460). [The large lug from transformer T1 (1-544) must make direct contact with the metal
surface of output inductor L1 (1-430).] Attach the black 10 AWG wires with lug (1-182) and lug
(1-196) to the output inductor L1 (1-430) with screw (1-608), washer (1-607), washer (1-609), and
nut (1-610). [The large lug (1-182) must make direct contact with the metal surface of output
inductor L1 (1-430).] Torque bolt (1-445) and screw (1-608) to 45 to 50 lb-in (5.0 to 5.7 N-m).
C. (Refer to IPL Figure 1, Sheet 5, IPL Figure 3, and IPL Figure 4.) To assemble the A3 Rear Heat
Sink Assembly (1-270), do the procedures that follow as are necessary. Use the instructions
given in paragraph 4.A. and 4.C. to install transistor Q1 (3-45) and voltage-regulator microcircuit
U9 (3-80) on the transistor mounting heat-sink (3-115) of the A3A1 Circuit Card Assy (1-290).
Connect the wiring from resistors R90 and R91 (4-235) to the A3A2 Circuit Card Assy (1-285).
Twist and solder the wires from resistor R90 to E1 and E2 on the A3A2 Circuit Card Assy. Twist
and solder the wires from resistor R91 to E3 and E4 on the A3A2 Circuit Card Assy. Install
resistors R90 and R91 (4-235) on the rear heat sink (1-305) with screws (1-288) and washers
(1-287).
Attach the lug (3-425) from E1 on the A3A1 Circuit Card Assy and the lug (4-470) from E5 on the
A3A2 Circuit Card Assy to the rear heat sink (1-305). Use screw (1-272) and washer (1-273) to
attach these lugs (3-425 and 4-470) to the rear heat sink (1-305). Torque screw (1-272) to
5 to 7 lb-in (0.6 to 0.8 N-m). Attach the A3A1 Circuit Card Assy (1-290) and the A3A2 Circuit Card
Assy (1-285) to the rear heat sink (1-305) with screws (1-300), washers (1-295), and washers
(1-284). Carefully turn each of the two screws one full turn at a time to connect the A6P1
connector (1-186) to the J1 connector (3-25) of the A3A1 Circuit Card Assy (1-290).
D. (Refer to IPL Figure 1, Sheet 4.) To assemble the A2 Right Heat Sink Assembly (1-310), do the
procedures that follow as are necessary. Use the instructions given in paragraph 4.A. and 4.B. to
install power-switch transistors Q1 and Q2 (1-340) on the right heat sink (1-315). Use the
instructions given in paragraph 5 to install the A2A1 Circuit Card Assy (1-390) on the right heat
sink (1-315). To attach snubber inductor L1 (1-370) to the right heat sink (1-315), first apply thread
lock sealant (refer to paragraph 2., Materials) to the threads of screws (1-385). Attach the snubber
inductor L1 (1-370) to the right heat sink (1-315) with screws (1-385) and washers (1-375). Use
the instructions given in paragraph 6.B.(2) to connect the red 14 AWG wire from snubber inductor
L1-1 (1-370) to the A1A2 Circuit Assy (2-135).
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E. (Refer to IPL Figure 1, Sheet 6.) To attach the terminal block assembly A5 (1-105) to the front
panel (1-65), first apply thread lock sealant (refer to paragraph 2., Materials) to the threads of
screws (1-106). Attach the terminal block assembly A5 (1-105) to the front panel (1-65) with
screws (1-106), washers (1-108), washers (1-107), and nuts (1-109). Torque screws (1-106) to
8 to 11 lb-in (0.9 to 1.2 N-m).
Attach the A5A1 Filter Cap Assy (1-160) to the terminal block assembly A5 (1-105) as follows.
Washer (1-142), washer (1-141), and nut (1-140) attach the A5A1 Filter Cap Assy to the smaller
negative terminal of the terminal block (1-137). Washer (1-145), washer (1-144), and nut (1-143)
attach the A5A1 Filter Cap Assy to the larger positive terminal of the terminal block (1-137).
Torque nuts (1-140 and 1-143) to 70 to 100 lb-in (7.9 to 11.3 N-m).
F. To completely assemble the Battery Charger, do the procedures that follow as are necessary.
Use the instructions given in paragraph 6.A. to install diode CR1 (2-45) in the A1 Input Assembly.
Use the instructions given in paragraph 6.B. to install the A1 Input Assembly (1-35) into the
Battery Charger. Paragraph 6.B. also gives the instructions to attach most of the other assemblies
and the wiring that are necessary to assemble the Battery Charger.
G. If necessary, attach the Front Panel (1-65) to A4 Left Heat Sink Assembly (1-405) with screws
(1-67) and washers (1-68). Attach the bottom cover (1-15) and the top cover (1-5) to the Battery
Charger to complete the procedure.
4. Mounting Details for Insulated Components
A. General
(1) These general mounting details for insulated components are related to the installation of
power-switch transistors A2Q1 and A2Q2 (1-340), transistor A3A1Q1(3-45), and voltage-
regulator microcircuit A3A1U9 (3-80).
(2) Before you install these insulated components, make sure all surfaces are clean and do not
have unwanted particles. Make sure all surfaces have smooth edges. This will let these
component surfaces make better contact when they are installed.
B. Transistors A2Q1/A2Q2
Some disassembly of the A2 Right Heat Sink Assy is necessary to install power-switch transistors
A2Q1 and A2Q2.
(1) (Refer to Figure 7001.) Do a check of the screw-hole counterbores in the right heat sink
(1-315). The counterbores should be filled with silicon adhesive, except for the screw hole.
Silicon adhesive should not be damaged and it should be even with the top-edge of the
counterbore. If the silicon adhesive does not meet these conditions, it will be necessary to fill
the screw-hole counterbores with new silicon adhesive. This must be done before the
power-switch transistors A2Q1 and A2Q2 (1-340) are installed.
Page 7004
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(2) If it is necessary to fill the screw-hole counterbores, remove the old silicon adhesive and
clean the counterbores thoroughly. Carefully, fill the counterbore with silicon adhesive
(3145-Clear; refer to paragraph 2., Materials).
NOTE: Do not put too much silicon adhesive in the counterbore. Too much silicon adhesive
can flow out of the counterbore and onto the insulator when the screw is installed.
This can prevent good thermal conduction between the transistors and the heat
sink.
NOTE: Before the silicon adhesive dries, make sure power-switch transistors A2Q1 and
A2Q2 are installed and screws are attached. If not, the dried silicon adhesive could
block the screw holes and prevent screw attachment.
(3) It may be necessary to replace the selected insulating washer (1-350) during the power-
switch transistors A2Q1 and A2Q2 installation. The procedure to make the correct selection
of the insulating washer for replacement follows:
(a) Measure the thickness of the flange on power-switch transistors A2Q1 and A2Q2
(1-340). The selection of the insulating washer (1-350) must match the thickness of
this flange.
(b) Make the selection of the insulating washer (1-350) to attach power-switch transistors
A2Q1 and A2Q2 from the IPL Figure 1 item numbers given below.
FLANGE THICKNESS IPL FIGURE 1. ITEM NO.

0.050 to 0.073 inch (1.9 mm) 1-350

0.074 to 0.086 inch (2.2 mm) 1 -350A
0.087 to 0.111 inch (2.8 mm) 1-350B
0.112 to 0.135 inch (3.4 mm) 1-350C
Page 7005
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Figure 7001
Heat Sink Counterbore
24-31-04
Page 7006
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(4) To install the power-switch transistors A2Q1 and A2Q2 (1-340) on the right heat sink
(1-315), put new insulators (1-335) on the heatsink surface.
Also, you can inspect the old selected insulating washers (1-350) [refer to paragraph 4.B.(3)]
and if they pass the inspection, you can use them again.
(5) Install the power-switch transistors A2Q1 and A2Q2 (1-340) on insulators (1-335) and attach
to the right heat sink as follows:
CAUTION: DO NOT TORQUE THE SCREWS TOO MUCH. THIS COULD DAMAGE THE
INSULATOR AND THE INSULATING WASHER. TORQUE THE SCREWS TO
4 LB-IN (0.5 N-M) AT THE START. TIGHTEN THE SCREWS MORE (UP TO 6 LB-IN
[0.7 N-M]) IF NECESSARY.
(a) Find the two holes in the right heat sink (1-315) where the brown wires come through
from A2A1 Circuit Card Assy. Near these holes, attach power-switch transistors A2Q1
and A2Q2 (1-340) with screw (1-365), washer (1-346), washer (1-357), selected
insulating washer (1-350), and lug (1-345). Torque screw (1-365) to 4 to 6 lb-in (0.5 to
0.7 N-m).
(b) Also, attach power-switch transistors A2Q1 and A2Q2 (1-340) with screw (1-365),
washer (1-346), washer (1-357), selected insulating washer (1-350), and washer
(1-360). Torque screw (1-365) to 4 to 6 lb-in (0.5 to 0.7 N-m).
(c) Measure the insulation resistance of the installed power-switch transistors A2Q1 and
A2Q2 (1-340) with an ohmmeter. The metal-to-metal resistance from the component to
the heat sink surface where it is attached must be > 1 M  .
If this resistance is less than 1 M, remove the power-switch transistor A2Q1 or A2Q2.
Check for a damaged insulator or rough edges and unwanted particles on component
surfaces. Also, check for a short-circuit condition between the fasteners and the flange
of the power-switch transistors A2Q1 and A2Q2.
(d) Fill the gap between the fasteners for power-switch transistors A2Q1 and A2Q2
(1-340) and the transistor case with silicon adhesive. Fill the gap with silicon adhesive
(3145-Clear; refer to paragraph 2., Materials). This will keep fluids and unwanted
material out of the gap that could cause a short-circuit condition. Clean off excess
silicon adhesive.
(e) If necessary, use the instructions in paragraph 5. to install the A2A1 Circuit Card Assy
(1-390) on the right heat sink (1-315).
(f) Use High-Temp solder Sn96.3Ag3.7 or equivalent to solder the wires from A2A1
Circuit Card Assy to the leads of power- switch transistors A2Q1 and A2Q2 (1-340) as
follows:
1 (Refer to IPL Figure 1 and IPL Figure 5.) If necessary, insert the brown 14 AWG
wire from the A2A1 Circuit Card Assy E26 through the hole in the right heat sink
and solder it to lug (1-345) of power-switch transistor A2Q1 - Fill the hole with
silicon adhesive (3145-Clear; refer to paragraph 2., Materials).
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2 Twist the yellow 22 AWG wire from A2A1E28 with the orange 22 AWG wire from
A2A1T2-3 for a minimum of three twists per 1 inch (2.5 cm). Solder the yellow 14
AWG wire from A2A1 Circuit Card Assy E24 and the yellow 22 AWG wire from
E28 to the emitter of power-switch transistor A2Q1. Solder the red 22 AWG wire
from A2A1 Circuit Card Assy E25 and the orange 22 AWG wire from T2-3 to the
base of power-switch transistor A2Q1.
NOTE: It is permitted to splice the orange 22 AWG wire from T2-3 to get
sufficient lead length for the connection to the base of power-switch
transistor A2Q1.
3 (Refer to IPL Figure 1 and IPL Figure 5.) If necessary, insert the brown 14 AWG
wire from the A2A1 Circuit Card Assy E20 through the hole in the right heat sink
and solder it to lug (1-345) of power-switch transistor A2Q2. Fill the hole with
silicon adhesive (3145-Clear; refer to paragraph 2., Materials).
4 Twist the yellow 22 AWG wire from A2A1E29 with the orange 22 AWG wire from
A2A1T3-3 for a minimum of three twists per 1 inch (2.5 cm). Solder the yellow 14
AWG wire from A2A1 Circuit Card Assy E18 and the yellow 22 AWG wire from
E29 to the emitter of power-switch transistor A2Q2. Solder the red 22 AWG wire
from A2A1 Circuit Card Assy E19 and the orange 22 AWG wire from T3-3 to the
base of power-switch transistor A2Q2.
NOTE: It is permitted to splice the orange 22 AWG wire from T3-3 to get
sufficient lead length for the connection to the base of power-switch
transistor A2Q2.
(6) After the installation of A2Q1/A2Q2, install the transistor cover (1-320) with screw (1-325)
and washer (1-330).
C. Transistor A3A1Q1 and Voltage-Regulator Microcircuit A3A1U9
Some disassembly of the A3 Rear Heat Sink Assy is necessary to install transistor Q1 and
voltage-regulator microcircuit U9.
(1) (Refer to Figure 7001.) Do a check of the screw-hole counterbores in the transistor mounting
heat-sink (3-115). The counterbores should be filled with silicon adhesive, except for the
screw hole. Silicon adhesive should not be damaged and it should be even with the top-
edge of the counterbore. If the silicon adhesive does not meet these conditions, it will be
necessary to fill the screw-hole counterbores with new silicon adhesive. This must be done
before the transistor Q1 (3-45) and voltage-regulator microcircuit U9 (3-80) are installed.
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(2) If it is necessary to fill the screw-hole counterbores, remove the old silicon adhesive and
clean the counterbores thoroughly. Carefully, fill the counterbore with silicon adhesive
(3145-Clear; refer to paragraph 2., Materials).
NOTE: Do not put too much silicon adhesive in the counterbore. Too much silicon adhesive
can flow out of the counterbore and onto the insulator when the screw is installed.
This can prevent good thermal conduction between the transistors and the heat
sink.
NOTE: Before the silicon adhesive dries, make sure transistor Q1 and voltage-regulator
microcircuit U9 are installed and screws are attached. If not, the dried silicon
adhesive could block the screw holes and prevent screw attachment.
(3) Measure the thickness of the flange on transistor Q1 (3-45) and voltage-regulator
microcircuit U9 (3-80). They must match the thickness of the old insulating washers (3-60
and 3-85). If the old insulating washers pass the inspection, you can use them again. If they
do not pass inspection, you must use new insulating washers (3-60 and 3-85).
(4) To install the transistor Q1 (3-45) and voltage-regulator microcircuit U9 (3-80) on the
transistor mounting heat-sink (3-115), put new insulators (3-75 and 3-105) on the heatsink
surface.
(5) Install the transistor Q1 (3-45) and voltage-regulator microcircuit U9 (3-80) on insulators
(3-75 and 3-105) and attach it to the transistor mounting heat-sink as follows:
(a) Find the hole in the transistor mounting heat-sink (3-115) where white wire 20 AWG
comes through from the A3A1 Circuit Card Assy terminal C. Near this hole, attach
transistor Q1 (3-45) with screw (3-52), washer (3-58), washer (3-55), insulating washer
(3-60), washer (3-65), and lug (3-70). Torque screw (3-52) to 2 to 3 lb-in (0.2 to 0.3
N-m).
(b) Also, attach transistor Q1 (3-45) with screw (3-52), washer (3-58), washer (3-55),
insulating washer (3-60), and washer (3-65). Torque screw (3-52) to 2 to 3 lb-in (0.2 to
0.3 N-m).
(c) Find the hole in the transistor mounting heat-sink (3-115) where white wire 20 AWG
comes through from the A3A1 Circuit Card Assy terminal 3. Near this hole, attach
voltage-regulator microcircuit U9 (3-80) with screw (3-100), washer (3-101), washer
(3-110), insulating washer (3-85), and lug (3-95). Torque screw (3-100) to 4 to 6 lb-in
(0.5 to 0.7 N-m).
(d) Also, attach voltage-regulator microcircuit U9 (3-80) with screw (3-100), washer
(3-101), washer (3-110), insulating washer (3-85), and washer (3-90). Torque screw
(3-100) to 4 to 6 lb-in (0.5 to 0.7 N-m).
(e) Measure the insulation resistance of the installed transistor Q1 (3-45) and voltage-
regulator microcircuit U9 (3-80) with an ohmmeter. The metal-to-metal resistance from
the component to the heat sink surface where it is attached must be > 1 M .
If this resistance < 1 M, remove the transistor Q1 or voltage-regulator microcircuit U9.
Check for a damaged insulator or rough edges and unwanted particles on component
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surfaces. Also, check for a short-circuit condition between the fasteners and the flange
of the transistor Q1 (3-45) and voltage-regulator microcircuit U9.
(6) Remove the black heat-shrink tubing from the four white wires 20 AWG that come from the
A3A1 Circuit Card Assy. Refer to IPL Figure 3, Sheets 11 and 12, and do the procedure that
follows to attach these wires:
(a) Refer to paragraph 2., Materials and cover the wires with approximately 0.75 inch
(1.9 cm) of new black heat-shrink tubing.
NOTE: Do not apply heat to the heat-shrink tubing at this time.
(b) Solder the two wires that come from A3A1 terminal B and A3A1 terminal E to the Base
and Emitter pins of transistor Q1 (3-45).
(c) Solder the two wires that come from A3A1 terminal 1 and A3A1 terminal 2 to pins 1
and 2 of voltage-regulator microcircuit U9 (3-80).
(d) Pull the heat-shrink tubing over the solder joints where the wires are attached to the
pins of the components. Apply heat to the heat-shrink tubing to decrease its diameter
to the correct size.
(7) Carefully pull the ends of the two white wires 20 AWG through the two holes in the transistor
mounting heat-sink (3-115). These wires come from the A3A1 Circuit Card Assy. Refer to
IPL Figure 3, Sheets 11 and 12, and do the procedure that follows to attach these wires:
(a) Solder the wire that comes from A3A1 terminal C to the lug (3-70) of transistor Q1
(3-45).
(b) Solder the wire that comes from A3A1 terminal 3 to the lug (3-95) of voltage-regulator
microcircuit U9 (3-80).
5. Replacement and Installation of Circuit Card Assy A2A1
A. General
This procedure gives the instructions to replace and install the A2A1 Circuit Card Assy. The
replacement for the 4-254311-01 (1-390), 4-254411-01 (1-390A), or 4-254411-02 (1-390C) circuit
cards should be the A2A1 Circuit Card Assy 4-254511-01 Assy (1-390B). This new configuration
A2A1 Circuit Card Assy (1-390B) improves the drive signal for power-switch transistors A2Q1 and
A2Q2.
NOTE: A 4-254311-01 or a 4-254411-01 A2A1 Circuit Card Assy that operates correctly can
replace one that is not operational, but, it can only be used on a 4-254309-01 A2 Right
Heatsink Assembly. A 4-254411-02 or a 4-254511-01 A2A1 CircuIt Card Assy can
replace a 4-254311-01 or a 4-254411-01, but, the 4-254309-01 A2 Right Heatsink
Assembly part number must be changed to 4-254409-01.
The instructions to do the A2A1 Circuit Card Assy replacement, the wiring change (if necessary),
and the part number change to the A2 Right Heatsink Assembly are given in paragraph B. The
instructions to install the A2A1 Circuit Card Assy are given in paragraph C.
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B. A2A1 Circuit Card Assy Replacement
If the A2A1 Circuit Card Assy (1-390, 1-390A, or 1-390C) is replaced with the new configuration
A2A1 Circuit Card Assy (1-390B), it may be necessary to make some changes to the wiring. If it is
necessary to do this change, use the procedures that are given in the paragraphs that follow.
(1) The orange wires from T2-3 and T3-3 on A2A1 Circuit Card Assy (1-390B) must be a
minimum of 9.5 inches (24.1 cm) in length. If necessary, the length of these wires can be
increased with a splice and the addition of a 4 inch (10.2 cm) length of orange 22 AWG wire.
The procedure to increase the wire length follows:
(a) To prepare the orange wire from T2-3 on A2A1 Circuit Card Assy (1-390B) for the
splice, remove the correct amount of insulation from the end of the wire. Also, remove
the correct amount of insulation from one end of the 4 inch (10.2 cm) length of orange
22 AWG wire (refer to paragraph 2., Materials).
(b) Attach a splice (refer to paragraph 2., Materials) between the end of the orange wire
from T2-3 and the end of the 4 inch (10.2 cm) length of orange 22 AWG wire.
(c) Cut a 1 inch (2.5 cm) length of 0.125 ID heat-shrink tubing (refer to paragraph 2.,
Materials) and put it over the splice. Apply heat to the heat-shrink tubing to decrease
its diameter to the correct size.
(d) To prepare the orange wire from T3-3 on A2A1 Circuit Card Assy (1-390B) for the
splice, remove the correct amount of insulation from the end of the wire. Also, remove
the correct amount of insulation from one end of the 4 inch (10.2 cm) length of orange
22 AWG wire (refer to paragraph 2., Materials).
(e) Attach a splice (refer to paragraph 2., Materials) between the end of the orange wire
from T3-3 and the end of the 4 inch (10.2 cm) length of orange 22 AWG wire.
(f) Cut a 1 inch (2.5 cm) length of 0.125 ID heat-shrink tubing (refer to paragraph 2.,
Materials) and put it over the splice. Apply heat to the heat-shrink tubing to decrease
its diameter to the correct size.
(2) Cut, prepare, and solder a 6 inch (15.2 cm) length of yellow 22 AWG wire (refer to
paragraph 2., Materials) to terminal E28 on A2A1 Circuit Card Assy (1-390B). Twist this
yellow wire with the orange wire from T2-3 a minimum of three twists per 1 inch (2.5 cm).
(3) Cut, prepare, and solder a 6 inch (15.2 cm) length of yellow 22 AWG wire (refer to
paragraph 2., Materials) to terminal E29 on A2A1 Circuit Card Assy (1-390B). Twist this
yellow wire with the orange wire from T3-3 a minimum of three twists per 1 inch (2.5 cm).
(4) Use a tiedown strap (refer to paragraph 2., Materials) to attach the twisted wire-pair from
E28/T2-3 to the wires from terminals E24, E25, and E26 near T1 on A2A1 Circuit Card Assy
(1-390B).
(5) Use a tiedown strap (refer to paragraph 2., Materials) to attach the twisted wire-pair from
E29/T3-3 to the wires from terminals E18, E19, and E20 on A2A1 Circuit Card Assy
(1-390B).
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(6) Use a tiedown strap (refer to paragraph 2., Materials) to attach the twisted wire pairs from
E29/T3-3 and the wires from terminals E18, E19, and E20 to a terminal near E24 A2A1
Circuit Card Assy (1-390B).
(7) Use High-Temp solder Sn96.3Ag3.7 or equivalent to solder the wires from A2A1 Circuit
Card Assy to the leads of power-switch transistors A2Q1 and A2Q2 (1-340) as follows:
(a) (Refer to IPL Figure 1 and IPL Figure 5.) If necessary, insert the brown 14 AWG wire
from the A2A1 Circuit Card Assy E26 through the hole in the right heat sink (1-315)
and solder it to lug (1-345) at power-switch transistor A2Q1. Fill the hole with silicon
adhesive (3145-Clear; refer to paragraph 2., Materials).
(b) Solder the yellow 14 AWG wire from A2A1 Circuit Card Assy E24 and the yellow 22
AWG wire from E28 to the emitter of power-switch transistor A2Q1.
(c) Solder the red 22 AWG wire from A2A1 Circuit Card Assy E25 and the orange 22
AWG wire from T2-3 to the base of power-switch transistor A2Q1.
(d) (Refer to IPL Figure 1 and IPL Figure 5.) If necessary, insert the brown 14 AWG wire
from the A2A1 Circuit Card Assy E20 through the hole in the right heat sink (1-315)
and solder it to lug (1-345) at power-switch transistor A2Q2. Fill the hole with silicon
adhesive (3145-Clear; refer to paragraph 2., Materials).
(e) Solder the yellow 14 AWG wire from A2A1 Circuit Card Assy E18 and the yellow 22
AWG wire from E29 to the emitter of power-switch transistor A2Q2.
(f) Solder the red 22 AWG wire from A2A1 Circuit Card Assy E19 and the orange 22
AWG wire from T3-3 to the base of power-switch transistor A2Q2.
(8) If necessary, install the transistor A2Q1/A2Q2 cover (1-320) with screw (1-325) and washer
(1-330).
(9) After the installation of the A2A1 Circuit Card Assy (1-390B), change the part number
(4-254309-01) of the old A2 Right Heatsink Assembly (1-310) to 4-254409-01.
C. A2A1 Circuit Card Assy Installation
The procedures that follow give the instructions to install the A2A1 Circuit Card Assy on the right
heat sink.
(1) Attach the A2A1 Circuit Card Assy (1-390) on the right heat sink (1-315) with screw (1-395)
and washer (1-400).
(2) (Refer to IPL Figure 1, IPL Figure 4, and IPL Figure 5.) Carefully turn each of the two
screws one full turn at a time to connect the P1 connector (5-55) from the A2A1 Circuit Card
Assy (1-390) to the A3A2 Circuit Card Assy connector J1 (4-25).
(3) Connect the blue 14 AWG wire with lug (5-85) from the A1A2 Circuit Assy (2-135) terminal
post E1 to the A2A1 Circuit Card Assy (1-390) terminal post E1 with screw (5-95), washer
(5-100), and washer (5-101).
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(4) Connect the red 14 AWG wire with lug (5-85) from the snubber inductor L1 -2 (1-370) to the
A2A1 Circuit Card Assy (1-390) terminal post E3 with screw (5-95), washer (5-100), and
washer (5-101).
(5) Connect the brown 14 AWG wire with lug (5-85) from A1A2 Circuit Assy (2-135) terminal
post E4 to the A2A1 Circuit Card Assy (1-390) terminal post E16 with screw (5-95), washer
(5-100), and washer (5-101).
6. Installation of Diode A1CR1 and A1 Input Assembly
A. Installation of Diode A1CR1
(1) (Refer to IPL Figure 2.) Install diode CR1 (2-45) onto the chassis (2-5) of the A1 Input
Assembly with screws (2-46), washers (2-47), and nuts (2-48).
(2) (Refer to DISASSEMBLY Figure 3001.) Solder three wires (E1 green, E2 brown, and E3
red) from the A1A1 Capacitor Assy (2-115) to diode CR1 (2-45). Solder two wires (yellow
and brown) from the dual unit inductor L2, L4 (2-35) to diode CR1 (2-45). The yellow wire
goes to CR1 + terminal and the brown wire goes to CR1 - terminal.
B. Installation of A1 Input Assembly
(1) To install the A1 Input Assembly and partially assemble the Battery Charger, do the
procedure that follows:
NOTE: This procedure assumes the Front Panel, A4 Left Heat Sink Assy, heat shield, and
A3 Rear Heat Sink Assy are assembled and are attached together.
(a) Install the A1 Input Assembly (1-35) into the Battery Charger and attach it to the Front
Panel (1-65) with screws (1-50), screws (1-54), and washers (1-55).
(b) On the Front Panel (1-65) and immediately below the Terminal Block Assy A5 (1-105),
install screws (1-46, not shown) and washers (1-41, not shown) to attach the capacitor
shield (2-10) to the front panel.
(c) Attach the left side of the A1 Input Assembly (1-35) to the bottom of the A4 Left Heat
Sink Assembly (1-405) with screws (1-47) and washers (1-40).
(d) Attach the A2 Right Side Heat Sink (1-310) to the Front Panel (1-65) with screws
(1-67) and washers (1-68).
(e) To attach the A2 Right Heat Sink Assy (1-310) to A1 Input Assembly (1-35), first apply
thread lock sealant (refer to paragraph 2., Materials) to the threads of screw (1-57).
Install screws (1-45) and washers (1-40), and screw (1-57) and washer (1-40).
(f) Attach the A2 Right Heat Sink Assy (1-310) to the heat shield (1-205) with screw
(1-206) and washer (1-209).
(g) Attach the A2 Right Heat Sink Assy (1-310) to the A3 Rear Heat Sink Assy (1-270) with
screws (1-280) and washers (1-275).
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(2) Do the procedure that follows to connect the wires that go to and come from the A1
Assembly.
(a) Connect the wires with lugs to the A1A2 Circuit Assy (2-135) terminal posts (E1, E2,
E4, E5 and E7 - not shown) as follows:
1 Connect the blue 14 AWG wire with lug from E1 of the A2A1 Circuit Card Assy
(1-390) to A1A2 Circuit Assy (2-135) terminal post E1 with screw (MS51957-27 -
not shown), washer (MS35338-136 - not shown), and washer (MS15795-805 -
not shown).
2 Connect the white 14 AWG wire with lug from transformer T1 (1-544) and the two
white 18 AWG wires with lug from resistors R1 and R2 (1-415) to A1A2 Circuit
Assy (2-135) terminal post E2 with screw (MS51957-27 - not shown), washer
(MS35338-136 - not shown), and washer (MS15795-805 - not shown).
3 Connect the brown 14 AWG wire with lug from E16 of the A2A1 Circuit Card Assy
(1-390) to A1A2 Circuit Assy (2-135) terminal post E4 with screw (MS51957-27-
not shown), washer (MS35338-136-not shown), and washer (MS15795-805 - not
shown).
4 Connect the red 14 AWG wire with lug from snubber inductor L1-1 (1-370) and
the white 14 AWG wire with lug from transformer T1 (1-544) to A1A2 Circuit Assy
(2-135) terminal post E5 with screw (MS51957-27 - not shown), washer
(MS35338-136 - not shown), and washer (MS15795-805 - not shown).
5 Connect the black 16 AWG wire with lug from capacitors C1 and C2 (1-411) to
A1A2 Circuit Assy (2-135) terminal post E6 with screw (MS51957-27 - not
shown), washer (MS35338-136 - not shown), and washer (MS15795-805 - not
shown).
(b) Twist and connect the two black wires with lugs (1-195) to the Front Panel (1-65) with
screw (1-86), washer (1-87), washer (1-88), and nut (1-89).
(c) Twist and connect the three green wires with lugs (1-197) from connector A6J1 (1-189)
to inductor A1L1 (2-30) at terminals 1, 3, and 5 with screws (1-264), washers (1-266),
and washers (1-265).
(d) Connect the two black wires with lugs (1-584 and 1-195) to inductor A1L1 (2-30) at
terminal 7 with screw (1-264), washer (1-267), and washer (1-265).
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FITS AND CLEARANCES
1. General
Special fits and clearances that are necessary for correct Battery Charger operation are given in this
section and in the ASSEMBLY section.
2. Fastener Torque Values
Battery Charger fasteners must be tightened to the torque values given in Table 8001.
Table 8001
Battery Charger Fastener Torque Values
IPL FIG/ITEM
TORQUE (lb-in) [N-m] PART LOCATION/DESCRIPTION
NUMBER
1-106 8 to 11 lb-in [0.9 to 1.2 N-m] A5 Terminal Block Assy Screw
1-114, 1-129 Install Finger Tight-Torqued in A5 Terminal Block Assy (DC Output to Battery
Aircraft to 100 ± 10 lb-in Connection) Nut
[11.3 ± 1.1 N-m]
1-140, 1-143 70 to 100 lb-in [7.9 to 11.3 N-m] A5 Terminal Block Assy Nut
1-272 5 to 7 lb-in [0.6 to 0.8 N-m] A3A1E1 and A3A2E5 Ground Lug Screws
1-365 4 to 6 lb-in [0.5 to 0.7 N-m] A2Q1 and A2Q2 Screws
1-445 45 to 50 lb-in [5.1 to 5.7 N-m] Output Inductor A4L1 Bolt for Transformer
A4T1 Lug Connection
1-495 25 to 30 lb-in [2.8 to 3.4 N-m] A4A1 Output Diode Assy Rectifier CR1/CR2
1-606 45 to 50 lb-in [5.1 to 5.7 N-m] A4A1 Output Diode Assy Screw for Lug (1-196)
and Lug (1-182) Connection
1-608 45 to 50 lb-in [5.1 to 5.7 N-m] Output Inductor A4L1 Bolt for Lug (1-196) and
Lug (1-182) Connection
3-52 2 to 3 lb-in [0.2 to 0.3 N-m] A3A1Q1 Screw
3-100 4 to 6 lb-in [0.5 to 0.7 N-m] A3A1U9 Screw
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BLANK
THIS PAGE
INTENTIONALLY
24-31-04
Page 8002
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4-254
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT
1. General
This section contains summary lists of the tools, fixtures, test equipment, and materials recommended
for use in other sections of this manual.
2. Tools
All tools, fixtures, and equipment necessary to do the procedures in this manual are listed in Table
9001. This list includes both special and standard equipment. Equivalent alternatives can be used for
the items given below.
Table 9001
Special Tools, Fixtures, and Equipment
NOMENCLATURE PART NUMBER/ SOURCE PURPOSE

SPECIFICATION (VENDOR)
Source, 115 V ac input 115 ± 1.0 V ac, Various Testing

400 Hz 3-phase, 20 A
Variable Transformer F136, 0 - 140 V ac, 20 A Superior Electric Testing

(3 necessary) (V58474)
Megohmmeter 1863, 500 V dc ± 2.5% QuadTech (V0PK96) Testing

Current Shunt HA100-100, 100 A, 100 mV EMPRO (V03030) Testing

or greater, ± 0.25%
Oscilloscope 465B, 100 MHz, 3% Tektronix (V80009) Testing
Decade Resistor Box 1433, 0.02 - 0.1% QuadTech (V0PK96) Testing
Power Supply, External HP6269B, 40 V dc, 50 A Agilent Technologies Testing

(V2D895)
Digital Multimeter 8050A or 8840A, Fluke (V0HYG7) Testing

(2 necessary) 0 - 200 V ac, 0 - 200 V dc,
0 - 200 mA (Max)
Current Probe P6021, 3% Tektronix (V80009) Testing

or
Volt-Amp-Wattmeter 0.5% (current) Electrical Instrument Testing
(VAW Meter) 0.75% (voltage) Services (V32590)
Stopwatch 0.1 second resolution Various Testing
Connector J1 BACC45FT14-12S, Battery Amphenol (V02660) Testing

Charger connection
Switch (4 necessary) 1 A, SPST Various Testing
Reverse Voltage Protection 1N1184, > 25 A Not Specified Testing

Diode and Isolation Diode
(2 necessary)
Page 9001
24-31-04 Nov 14/14
4-254
Table 9001
Special Tools, Fixtures, and Equipment
5 V dc Power Supply PA32-2A, 5 V dc, 1 A Kikusui (V61993) Testing
Light Emitting Diode (LED) MV5025A, 5 V dc Quality Technologies Testing

Corp
(V0MS63)
Circuit Breaker 7.5 A, 140 V ac, 400 Hz, Various Testing

3-phase
Resistor 1 M, 5%, 1/4 W Various Testing
Resistor RLR07C5600GS or Various Testing

RLR07C5600GR,
560 , 1/4 W
Capacitor1 10,000 µF, 75 V dc Various Testing
Variable Resistive Load2 3-2283 ELDEC (V08748) Testing
Abrading Tool Dremel Moto-Flex, Model Dremel Mfg. (V18531) Repair

332-5
Hot Air Dryer 220 °F (104 °C) Commercial Repair
Oven 140 °F (60 °C) Commercial Repair

Insertion Tool MS24256A20, 20 gauge Commercial Repair
Insertion Tool MS24256A16, 16 gauge Commercial Repair
Crimping Tool MS22520/1-01 Commercial Repair
Removal Tool MS24256R20, 20 gauge Commercial Repair
Removal Tool MS24256R16, 16 gauge Commercial Repair
1. The 10,000 µF electrolytic capacitor must be temporarily disconnected from the Variable
Resistive Load to do the Overvoltage Protection Tests, step (4)(a)3. When you set up the test
circuit shown in Figure 1003, make sure you can easily disconnect and reconnect this
capacitor.
2. The Variable Resistive Load is made to test the 4-254 with the procedures in this manual.
Page 9002
24-31-04 Oct 5/12
4-254
3. The Variable Resistive Load must have the capability to conduct a load current that can change
from 8 A at 10 V dc to 64 A at 28 V dc. Maximum voltage for this Variable Resistive Load is 39
V dc; maximum power is 1800 W. The Variable Resistive Load must be cooled, have the
correct wiring to conduct the current, and have a wide range of resistance steps. A schematic
diagram for a Variable Resistive Load is shown in Figure 1001, and the related parts list is
given in Table 1001. The current range of the Variable Resistive Load that is shown is
0 - 200 A.
A solid-state load can be used as an alternative to the Variable Resistive Load. If a solid state
load is used, it must operate in the Constant Resistance mode. Some solid state loads can
make the Battery Charger operation unstable. If the Battery Charger operation is not stable,
stop operation, and use a resistive load instead.
3. Materials
All materials necessary to do the procedures in this manual are listed in Table 9002. Equivalent
alternatives can be used for the items given below.

Materials
PART NUMBER/ SOURCE (VENDOR)

DESCRIPTION PURPOSE
SPECIFICATION
Low-lint Cloth - Commercial Cleaning
Stoddard Solvent MIL-PRF-680, Type II Commercial Cleaning
Isopropyl Alcohol TT-I-735 Commercial Cleaning/Repair
Soft bristled – Commercial Cleaning

nonmetal brush
Low pressure – Commercial Cleaning

compressed air
Insulating Compound PC12-007 or Dexter Corporation Repair

PC12-007M (V12405)
Copper Pad Commercial, 0.002 inch Commercial Repair

(0.05 mm) thick, coated with
tin
Conformal Coating Amber Humiseal, 1A20 Chase Corporation Repair

(V99109)
Solder Sn63Pb37 (J-STD-006) with Commercial Repair/Assembly

ROL0 or ROL1 flux
(J-STD-004)
Solder, High-Temp Sn96.3Ag3.7 (J-STD-006) Commercial Repair/Assembly

with ROL0 or ROL1 flux
(J-STD-004)
Page 9003
24-31-04 Apr 17/15
4-254

Materials

DESCRIPTION PURPOSE
SPECIFICATION
Solder Wick Braid with ROL0 or ROL1 Commercial Repair
flux
Adhesive, Epoxy, 2216 B/A, Color: Gray 3M Company (V1A9T3) Repair

Two-Part
Powder, Colloidal Cab-O-Sil, M-5 Cabot Corporation Repair

Silica (V80798)
Wire, 24 AWG LW_0.51_C-32-N Commercial Repair
Wire, 18 AWG M22759/11-18-9, White Commercial Repair
Wire, 16 AWG LW_1.27_C-32-N Commercial Repair
Wire, 22 AWG M22759/11-22-3, Orange Commercial Repair
Wire, 22 AWG M22759/11-22-4, Yellow Commercial Repair
Wire, 14 AWG M22759/11-14-9, White Commercial Repair
Sleeving, 22 AWG TFE, 0.012 Wall, White Commercial Repair

Sleeving, 24 AWG TFE, 0.012 Wall, White Commercial Repair
Sleeving, 20 AWG TFE, 0.034 ID, Natural Commercial Repair
Sleeving, 16 AWG TFE, 0.053 ID, Natural Commercial Repair
Polyimide Tape 2345-1 Oak-Mitsui (V4M1M7) Repair
Lacing Tape 0.010 X 0.050 inch (0.254 X Commercial Repair

1.27 mm) Natural (Mil Spec
A-A-52081, #5)
Plastic Strap MS3367-4-9 Commercial Repair
Sealant, MIL-S-46163, Type 2, Grade- Commercial Assembly

Thread Locking N
Adhesive, Silicon RTV 3145-Clear Dow Corning Corp. Assembly

(V71984)
Encapsulant, Circalock 6709 with catalyst Lord Corp. (V29966) Assembly

Silicone 6731, Thermally
conductive RTV
Tubing, Heat- Thermofit RNF-100, Type 1, Tyco Electronics Corp. Assembly

shrinkable Black, 0.125 ID, (V06090)
Tiedown straps MS3367-4-9, Adjustable, Commercial Assembly

self-clinching plastic
Page 9004
24-31-04 Apr 17/15
4-254

Materials

DESCRIPTION PURPOSE
SPECIFICATION
Wire, 22 AWG M22759/11-22-3, 8 inches Commercial Assembly
(20.3 cm), Insulated, Orange
Wire, 22 AWG M22759/11-22-4, 12 inches, Commercial Assembly

(30.5 cm) Insulated, Yellow
Terminal splices Not Specified Commercial Assembly

(Qty 2)
Tubing, Heat- Thermofit RT-850, Tyco Electronics Corp. Assembly

shrinkable, Polyvinyl Kynar, tan, 0.125 ID (V06090)
Page 9005
24-31-04 May 25/12
4-254
BLANK
THIS PAGE
INTENTIONALLY
24-31-04
Page 9006
May 25/12
4-254
1. General
The Illustrated Parts List provides figures and tables for the parts that are in the Battery Charger. The
IPL figures show each major assembly of the equipment in a disassembled form. The tables show the
part numbers of the parts that are on the IPL figures.
A. Figure and Item Number Column
Each part on the parts list is given its own figure-item number. The item number can be used to
find the part on the IPL figure. A dash (–) before the item number identifies parts that are not
shown on the illustration.
B. Part Number Column
(1) The part number column gives part numbers for ELDEC parts, vendor parts, commercial
standard parts, or military standard parts.
(2) If a vendor part or standard part is equivalent to a part specification from ELDEC, the
nomenclature column gives the related ELDEC specification number (for example.
HE32-01, V08748).
C. Airline Part Number Column

The airline part number column is used by the operator to give local part numbers.
D. Nomenclature Column
(1) The nomenclature column uses the indenture system (....) to show the relationships of the
higher and lower assemblies. A repairable assembly has its detail parts given in the next
indenture below and to the right. The next higher assembly of any detail part may be found
in the indenture above and to the left.
(2) Parts that have a vendor code number (Vxxxxx) in the nomenclature column are available
through that approved vendor. Parts that do not have a vendor code number in parentheses
are either commercial standard parts, military standard parts, or ELDEC parts.
(3) Attaching parts immediately follow the part or assembly that they attach, and have the same
indenture. They start with the words ATTACHING PARTS, and stop with the symbol ***.
(4) Electrostatic Discharge (ESD) identifies a part that can be damaged by an electrical charge
that is generated by friction. Electrostatic Discharge Sensitive (ESDS) also identifies a part
that can be damaged by an electrical charge that is generated by friction. Obey standard
precautions when you touch, move, or do a preservation procedure on ESD or ESDS parts.
(5) Other words used in the Nomenclature column are defined below:
Optional: This part is optional to and interchangeable with other parts in the same item
number variant group or other item number if designated.
Superseded by (SUPSD BY): The part is replaced by and is not interchangeable with the
item number shown.
Page 10001
24-31-04 May 25/12
4-254
Supersedes (SUPSDS): The part replaces and is not interchangeable with the item number
shown.
Replaced by (REPLD BY): The part is replaced by and interchangeable with the item
number shown.
Replaces (REPLS): The part replaces and is interchangeable with the item number shown.
E. Effectivity Code Column
Within a figure, the letters that appear in the effectivity code column (EFFECT CODE) show parts
that have special use. A part that has an effectivity code must be used in the next higher
assembly that has the same effectivity code. The codes apply to a single figure only; the codes in
one figure are not related to the codes in another figure. Where no code is given, the part is used
on all configurations.
F. Units Per Assembly Column
Shows the quantity of a part that is used in the specific item number location. The letters RF
identify parts that are listed for reference only on this particular parts list. The letters AR identify
parts whose quantity may vary as required between similar assemblies.
2. Vendors Code, Name and Address
The Vendors Code, Name and Address List gives the information necessary to order parts from the
manufacturer. For non-standard parts, the nomenclature column of the parts list shows the vendor
code numbers in parentheses.
3. Equipment Designator Index
The Equipment Designator Index gives a cross-reference between equipment designators and the IPL
figure-item number of the part. The index shows the parts that have been given equipment designators
on the schematic diagrams. The index is in alpha-numerical order and follows the Vendors Code,
Name and Address list.
4. Numerical Index
The numerical index gives a cross-reference between a part number and the IPL figure-item number of
the part. The index gives all part numbers contained in the IPL. The index is in alpha-numerical order
and follows the Equipment Designator Index.
Page 10002
24-31-04 May 25/12
4-254
VENDOR CODE, NAME AND ADDRESS

CODE NAME AND ADDRESS CODE NAME AND ADDRESS
V0FRE0 Stancor Inc. V06090 Tyco Electronics Corporation
Monroe, CT 06468 300 Constitution Drive
Menlo Park, CA 94025-1140
V0HYG7 Fluke Corp.
1420 75th St. SW V06288 Edal Industries, Inc.
Everett, WA 98206 51 Commerce Street
East Haven, CT 06512-4113
V0MS63 Quality Technologies Corp.
3001 Orchard Pkwy. V06383 Panduit Corp.
San Jose, CA 95134-2017 17301 Ridgeland Ave.
Tinley Park, IL 60477-3093
V0PK96 Quadtech, Inc.
5 Clock Tower Pl. Ste. 210 V06540 Amatom Electronic Hardware Div.
Maynard, MA 01754-2530 (New Haven Mfg. Corp.)
446 Blake Street
V0ZK84 Micro-Dimensional Products New Haven, CT 06515-1238
199 West Spruce Street Cancelled/Replaced by V1YGB8
Norristown, PA 19401-3863
V07047 Ross Milton Co The
V00779 Tyco Electronics Corporation 262 Valley Road
2800 Fulling Mill Rd. Bldg.-38 Warrington, PA 18976
Middletown, PA 17057-3142
V07933 Fairchild Semiconductor Corp.

V01295 Texas Instruments Inc. 3001 Orchard Pkwy.
Semiconductor Group San Jose, CA 95134-2017
12500 T I Blvd.
Dallas, TX 75243-0592 V08740 Broen Sheet Metal Products Inc.
North Ville, MI 48167
V02114 Amperex Electronics Corp.
Saugerties, NY 12477 V08748 Crane Aerospace & Electronics
ELDEC Corporation
V02368 Rolex Company 16700 13th Ave. West
385 Hillside Ave. Lynnwood, WA 98037-8503
Hillside, NJ 07205-1123
V1A9T3 3M Company
V02660 Amphenol Corp. Adhesives Division
Spectra-Strip/ITD 3M Center
40-60 Delaware Ave. Saint Paul, MN 55144-1000
Sidney, NY 13838-1395
V1YGB8 Carry Manufacturing Company, Inc.
V03030 Empro Manufacturing Co., Inc. Amatom Electronic Hardwares
10920 E 59th Street 5 Pasco Hill Road
Indianapolis, IN 46236-8337 Cromwell, CT 06416-1012
Replaces V06540
V04713 Freescale Semiconductor Inc.
2100 E. Elliot Rd. V10400 Airborn Interconnect, Inc.
Tempe, AZ 85284-1806 4321 Air Born Dr.
Addison, TX 75001-5626
Page 10003
24-31-04 Nov 14/14
4-254

V12405 Henkel Loctite Corp. V27014 National Semiconductor Corp.
15051 E Don Julian Road 2900 Semiconductor Drive
City of Industry, CA 91746 P.O. Box 810839
Santa Clara, CA 95051-0606
V12517 Component Research Co., Inc.
1655-26th St. V29454 Johanson Dielectrics, Inc.
Santa Monica, CA 90404-4025 15191 Bledsoe Ave.
Sylmar, CA 91342
V12969 Micro USPD Inc.
580 Pleasant St. V29966 Lord Corp.
Watertown, MA 02472-2408 East Weymouth Operations
96 Moore Road
V15605 Eaton Corp. East Weymouth, MA 02189-2331
4201 N 27th Street
Milwaukee, WI 53216-1897 V3F511 Allied Electronics
Subsidiary of Allied Radio Corp.
V18310 Concord Electronics, Inc. Seattle, WA 98060
3300 47th Ave.
Long Island City, NY 11101-2430 V3N087 Mill-Max Mfg. Corp.
P.O. Box 300
V18531 Dremel Mfg. Company 190 Pine Hollow Rd.
4915 21st Street Oyster Bay, NY 11771-4704
Racine, WI 53408-1126
V3RMR9 Ferroxcube USA, Inc.
V18565 Parker-Hannifin Corp. 12280 Rojas Drive
Chomerics Div. El Paso, TX 79936-7713
77 Dragon Court
Woburn, MA 01801-1039 V30043 Solid State Devices, Inc.
14701 Firestone Blvd.
V19080 Robison Electronics Inc. La Mirada, CA 90638-5918
448 Sherwood Road
Paso Robles, CA 93447 V32590 Electrical Instrument Service, Inc.
25 Dock St.
V19645 Data Device Corporation Mount Vernon, NY 10550-5022
105 Wilbur Pl.
Bohemia, NY 11716-2426 V34333 Microsemi Corp-Integrated Products
11861 Western Ave.
V2D895 Agilent Technologies Inc. Garden Grove, CA 92841-2119
9780 S. Meridian Blvd.
Englewood, CO 80112-4026 V34371 Intersil Corporation
1001 Murphy Ranch Road
V20999 3M Company Milpitas, CA 95035-5680
Electrical Specialties Division
6801 River Place Blvd.
Austin, TX 78726-9000
V26073 Electrorack Products Company

1443 S Sunkist Street
Anaheim, CA 92806-5626
Page 10004
24-31-04 Oct 5/12
4-254

V34899 Fair-Rite Products Corp. V71279 Interconnection Products, Inc.
1 Commercial Row (Formerly Midland-Ross Corp.,
Walkill, NY 12589-0288 Cambion Division, Cambridge, MA)
2601 S. Garnsery St.
V4M1M7 Oak-Mitsui Inc. Santa Ana, CA 92707-3338
80 1st. St.
Hoosick Falls, NY 12090-1631 V71984 Dow Corning Corporation
2200 W Salzburg Road
V44655 Heico Ohmite, LLC Midland, MI 48686-0001
1600 Golf Rd. Ste. 850
Rolling Meadows, IL 60008-4204 V73734 Federal Screw Products, Inc.
9742 West Foster Street
V56289 Sprague Electric Co. Rosemont, IL 60018-5341
678 Main Street
Sanford, ME 04073-7003 V79963 Zierick Mfg. Co.
131 Radio Circle
V58474 Superior Electric Holding Group LLC Mount Kisco, NY 10549
Danaher Corporation
28 Spring Ln. Ste. 3 V80009 Tektronix, Inc.
Farmington, CT 06032-3140 14150 SW Karl Braun Dr.
P. O. Box 500
V60204 Fleck Co., Inc. Beaverton, OR 97077-0001
Auburn, WA 98002-1705
V80205 National Aerospace Standards
V61993 Kikusui Intl. Corp. Committee Aerospace Industries
1980 Orizaba Avenue Association of America, Inc.
Long Beach, CA 90804 1000 Wilson Blvd. Suite 1700
Arlington, VA 22209
V65238 Novacap, Inc.
25136 Anza Drive V80798 Cabot Corporation
Santa Clarita, CA 91355-0000 2 Seaport Lane Ste. 1300
Boston, MA 02210-2058
V67268 Defense Supply Center Columbus Open
Support Group Document Control Unit V81312 Winchester Electronics Corp.
3990 E. Broad St. 62 Barnes Industrial Road N
Columbus, OH 43218-3990 Wallingford, CT 06492-1846
V7L704 Hevi-Duty Electric V81349 Military Specifications

Div. of Sola Basic Industires Inc.
1717 Busse Road V81350 Joint Army/Navy Specifications
Elk Grove Village, IL 60007-5615 (JANTX/JANTXV)
V7M138 United Chemi-Con Mfg., Inc. V83330 Dialight Corp.

185 McNeil Rd. 1501 State Route 34 S
Lansing, NC 28643 Farmingdale, NJ 07727-3932
V88044 Aeronautical Standards Group

Dept. of Navy and Air Force
Page 10005
24-31-04 Oct 5/12
4-254

V96906 Military Standards
V99017 Caplugs LLC

2150 Elmwood Ave.
Buffalo, NY 14207-1984
V99109 Chase Corporation

128 First Street
Pittsburgh, PA 15238-3223
Page 10006
24-31-04 May 25/12
4-254
EQUIPMENT DESIGNATOR INDEX
EQUIPMENT EQUIPMENT EQUIPMENT

DESIGNATOR FIG. ITEM DESIGNATOR FIG. ITEM DESIGNATOR FIG. ITEM
A1 1- 35 A2A1T3 5- 35 A3A1CR10 3- 180

A1 2- 1 A2A1T4 5- 40 A3A1CR11 3- 180
A1A1 2- 115 A2L1 1- 370 A3A1CR12 3- 180
A1A1C1 2- 130 A2Q1 1- 340 A3A1CR14 3- 180
A1A1C2 2- 130 A2Q2 1- 340 A3A1CR15 3- 180
A1A1C3 2- 130 A3 1- 270 A3A1CR16 3- 180
A1A2 2- 135 A3A1 1- 290 A3A1CR17 3- 180
A1A2C1 2- 170 A3A1 3- 1 A3A1CR18 3- 180
A1A2C2 2- 170 A3A1C1 3- 195 A3A1CR19 3- 180
A1A2C3 2- 165 A3A1C2 3- 210 A3A1CR20 3- 180
A1A2C4 2- 165 A3A1C3 3- 205 A3A1CR22 3- 180
A1A2C5 2- 165 A3A1C4 3- 195 A3A1CR23 3- 180
A1A2C6 2- 165 A3A1C5 3- 210 A3A1CR24 3- 180
A1A2C7 2- 165 A3A1C6 3- 210 A3A1CR26 3- 180
A1A2C8 2- 165 A3A1C7 3- 194 A3A1CR27 3- 180
A1A2R1 2- 155 A3A1C8 3- 210 A3A1CR28 3- 180
A1A2R2 2- 155 A3A1C9 3- 210 A3A1CR29 3- 180
A1A2R3 2- 160 A3A1C10 3- 210 A3A1CR30 3- 181
A1C1 2- 175 A3A1C11 3- 210 A3A1J1 3- 25
A1C2 2- 175 A3A1C12 3- 210 A3A1Q1 3- 45
A1C3 2- 175 A3A1C13 3- 196 A3A1Q2 3- 150

A1CR1 2- 45 A3A1C14 3- 190 A3A1Q3 3- 150
A1CR2 2- 180 A3A1C15 3- 210 A3A1Q4 3- 155
A1CR3 2- 180 A3A1C16 3- 210 A3A1Q5 3- 155
A1CR4 2- 180 A3A1C17 3- 210 A3A1Q6 3- 155
A1CR5 2- 180 A3A1C18 3- 215 A3A1Q7 3- 150
A1CR6 2- 180 A3A1C19 3- 210 A3A1Q8 3- 150
A1CR7 2- 180 A3A1C20 3- 195 A3A1Q10 3- 150
A1L1 2- 30 A3A1C21 3- 215 A3A1Q11 3- 150
A1L2 2- 35 A3A1C22 3- 210 A3A1R1 3- 225
A1L3 2- 40 A3A1C23 3- 185 A3A1R2 3- 340
A1L4 2- 35 A3A1C24 3- 215 A3A1R3 3- 340
A1T1 2- 25 A3A1C25 3- 210 A3A1R4 3- 220
A2 1- 310 A3A1C26 3- 195 A3A1R5 3- 345
A2A1 1- 390 A3A1C28 3- 200 A3A1R6 3- 340
A2A1 5- 1 A3A1C29 3- 217 A3A1R7 3- 340
A2A1C1 5- 15 A3A1C30 3- 215 A3A1R8 3- 340
A2A1C2 5- 15 A3A1C31 3- 216 A3A1R9 3- 340
A2A1CR1 5- 30 A3A1C32 3- 430 A3A1R10 3- 305
A2A1CR2 5- 25 A3A1CR1 3- 180 A3A1R11 3- 250
A2A1CR3 5- 25 A3A1CR2 3- 180 A3A1R12 3- 355
A2A1CR4 5- 30 A3A1CR3 3- 180 A3A1R13 3- 250
A2A1P1 5- 55 A3A1CR4 3- 180 A3A1R14 3- 360
A2A1R1 5- 10 A3A1CR5 3- 180 A3A1R15 3- 340
A2A1R2 5- 10 A3A1CR6 3- 180 A3A1R16 3- 335
A2A1T1 5- 40 A3A1CR7 3- 180 A3A1R17 3- 350
A2A1T2 5- 35 A3A1CR9 3- 180 A3A1R18 3- 260
Page 10007
24-31-04 May 25/12
4-254

A3A1R19 3- 230 A3A1R67 3- 362 A3A2C10 4- 180

A3A1R20 3- 255 A3A1R68 3- 390 A3A2C11 4- 175
A3A1R21 3- 230 A3A1R69 3- 395 A3A2C12 4- 217
A3A1R22 3- 230 A3A1R70 3- 400 A3A2C13 4- 215
A3A1R23 3- 310 A3A1R71 3- 405 A3A2C14 4- 215
A3A1R24 3- 340 A3A1R72 3- 395 A3A2C15 4- 225
A3A1R25 3- 235 A3A1R73 3- 410 A3A2C16 4- 225
A3A1R26 3- 240 A3A1R74 3- 340 A3A2C17 4- 205
A3A1R27 3- 285 A3A1R75 3- 375 A3A2C18 4- 175
A3A1R28 3- 320 A3A1R76 3- 295 A3A2C19 4- 225
A3A1R30 3- 326 A3A1R77 3- 340 A3A2C20 4- 210
A3A1R31 3- 415 A3A1R78 3- 360 A3A2C21 4- 205
A3A1R32 3- 420 A3A1R79 3- 315 A3A2C22 4- 175
A3A1R33 3- 287 A3A1R80 3- 400 A3A2C23 4- 225
A3A1R34 3- 327 A3A1R81 3- 400 A3A2C24 4- 210
A3A1R35 3- 290 A3A1R82 3- 400 A3A2C25 4- 165
A3A1R36 3- 365 A3A1R83 3- 245 A3A2C27 4- 195
A3A1R37 3- 377 A3A1R84 3- 435 A3A2C28 4- 225
A3A1R38 3- 296 A3A1R85 3- 320 A3A2C29 4- 225
A3A1R39 3- 370 A3A1R86 3- 302 A3A2C30 4- 185
A3A1R40 3- 290 A3A1R87 3- 376 A3A2C31 4- 231

A3A1R41 3- 310 A3A1U1 3- 120 A3A2C32 4- 220
A3A1R42 3- 360 A3A1U2 3- 120 A3A2C33 4- 200
A3A1R43 3- 315 A3A1U3 3- 125 A3A2C34 4- 188
A3A1R44 3- 375 A3A1U4 3- 130 A3A2C35 4- 188
A3A1R45 3- 330 A3A1U5 3- 135 A3A2C37 4- 159
A3A1R46 3- 317 A3A1U6 3- 140 A3A2C38 4- 159
A3A1R46 3- 361 A3A1U7 3- 140 A3A2C39 4- 232
A3A1R47 3- 355 A3A1U8 3- 145 A3A2C40 4- 510
A3A1R48 3- 260 A3A1U9 3- 80 A3A2C41 4- 186
A3A1R49 3- 260 A3A1VR1 3- 170 A3A2C42 4- 525
A3A1R50 3- 420 A3A1VR2 3- 175 A3A2CR8 4- 137
A3A1R51 3- 360 A3A1VR3 3- 170 A3A2CR9 4- 137
A3A1R52 3- 265 A3A1VR4 3- 165 A3A2CR10 4- 137
A3A1R53 3- 270 A3A1VR5 3- 165 A3A2CR12 4- 125
A3A1R54 3- 405 A3A1VR6 3- 160 A3A2CR13 4- 130
A3A1R55 3- 340 A3A1VR7 3- 175 A3A2CR14 4- 135
A3A1R57 3- 340 A3A2 1- 285 A3A2CR15 4- 135
A3A1R58 3- 275 A3A2 4- 1 A3A2CR16 4- 135
A3A1R59 3- 300 A3A2C1 4- 182 A3A2CR17 4- 135
A3A1R60 3- 316 A3A2C2 4- 190 A3A2CR18 4- 125
A3A1R61 3- 280 A3A2C3 4- 187 A3A2CR19 4- 130
A3A1R62 3- 401 A3A2C4 4- 160 A3A2CR20 4- 135
A3A1R63 3- 380 A3A2C5 4- 230 A3A2CR21 4- 125
A3A1R64 3- 325 A3A2C6 4- 170 A3A2CR22 4- 130
A3A1R65 3- 385 A3A2C8 4- 184 A3A2CR23 4- 135
A3A1R66 3- 320 A3A2C9 4- 185 A3A2CR24 4- 135
Page 10008
24-31-04 May 25/12
4-254

A3A2CR25 4- 135 A3A2R11 4- 335 A3A2R61 4- 275

A3A2CR26 4- 135 A3A2R12 4- 380 A3A2R62 4- 240
A3A2CR27 4- 125 A3A2R13 4- 335 A3A2R63 4- 290
A3A2CR28 4- 130 A3A2R14 4- 365 A3A2R64 4- 255
A3A2CR29 4- 135 A3A2R15 4- 400 A3A2R65 4- 310
A3A2CR30 4- 137 A3A2R16 4- 406 A3A2R66 4- 300
A3A2CR31 4- 135 A3A2R17 4- 410 A3A2R67 4- 260
A3A2CR32 4- 135 A3A2R18 4- 425 A3A2R68 4- 305
A3A2CR33 4- 135 A3A2R22 4- 405 A3A2R69 4- 295
A3A2CR34 4- 135 A3A2R23 4- 455 A3A2R70 4- 270
A3A2CR35 4- 125 A3A2R24 4- 105 A3A2R71 4- 315
A3A2CR36 4- 125 A3A2R25 4- 285 A3A2R72 4- 385
A3A2CR37 4- 138 A3A2R26 4- 380 A3A2R73 4- 355
A3A2CR38 4- 135 A3A2R27 4- 340 A3A2R74 4- 275
A3A2CR39 4- 135 A3A2R28 4- 110 A3A2R75 4- 280
A3A2CR40 4- 146 A3A2R29 4- 355 A3A2R76 4- 395
A3A2CR41 4- 147 A3A2R30 4- 430 A3A2R77 4- 330
A3A2J1 4- 25 A3A2R31 4- 450 A3A2R78 4- 330
A3A2Q1 4- 115 A3A2R32 4- 386 A3A2R79 4- 390
A3A2Q2 4- 100 A3A2R33 4- 435 A3A2R80 4- 390
A3A2Q3 4- 115 A3A2R34 4- 245 A3A2R81 4- 325

A3A2Q4 4- 115 A3A2R35 4- 445 A3A2R82 4- 355
A3A2Q5 4- 115 A3A2R36 4- 350 A3A2R83 4- 405
A3A2Q6 4- 100 A3A2R37 4- 530 A3A2R84 4- 440
A3A2Q7 4- 95 A3A2R38 4- 360 A3A2R85 4- 250
A3A2Q8 4- 100 A3A2R39 4- 336 A3A2R86 4- 337
A3A2Q9 4- 95 A3A2R40 4- 341 A3A2R87 4- 355
A3A2Q10 4- 85 A3A2R41 4- 341 A3A2R88 4- 355
A3A2Q11 4- 95 A3A2R42 4- 355 A3A2R89 4- 345
A3A2Q12 4- 100 A3A2R43 4- 415 A3A2R90 4- 235
A3A2Q13 4- 95 A3A2R44 4- 415 A3A2R91 4- 235
A3A2Q14 4- 85 A3A2R45 4- 320 A3A2R92 4- 475
A3A2Q15 4- 90 A3A2R46 4- 320 A3A2R93 4- 480
A3A2Q16 4- 90 A3A2R47 4- 280 A3A2R94 4- 485
A3A2Q17 4- 100 A3A2R48 4- 265 A3A2R95 4- 520
A3A2Q18 4- 100 A3A2R49 4- 240 A3A2R96 4- 515
A3A2Q19 4- 120 A3A2R50 4- 290 A3A2R100 4- 535
A3A2Q20 4- 120 A3A2R51 4- 255 A3A2U1 4- 60
A3A2R1 4- 335 A3A2R52 4- 310 A3A2U2 4- 55
A3A2R2 4- 335 A3A2R53 4- 300 A3A2U3 4- 65
A3A2R3 4- 370 A3A2R54 4- 260 A3A2U4 4- 70
A3A2R4 4- 375 A3A2R55 4- 305 A3A2U5 4- 65
A3A2R5 4- 350 A3A2R56 4- 295 A3A2U6 4- 75
A3A2R6 4- 420 A3A2R57 4- 270 A3A2U7 4- 80
A3A2R7 4- 460 A3A2R58 4- 315 A3A2U8 4- 80
A3A2R8 4- 465 A3A2R59 4- 385 A3A2VR1 4- 145
A3A2R10 4- 370 A3A2R60 4- 355 A3A2VR2 4- 155
Page 10009
24-31-04 May 25/12
4-254

A3A2VR3 4- 140
A3A2VR4 4- 150
A3A2VR5 4- 150
A3A2VR6 4- 150
A4 1- 405
A4A1 1- 470
A4A1C1 1- 525
A4A1C2 1- 525
A4A1C3 1- 501
A4A1CR1 1- 495
A4A1CR2 1- 495
A4A1R1 1- 530
A4A1R2 1- 530
A4C1 1- 411
A4C2 1- 411
A4L1 1- 430
A4R1 1- 415
A4R2 1- 415
A4T1 1- 544
A5 1- 105
A5A1 1- 160
A5A1C1 1- 165
A5A1C2 1- 170
A5A1C3 1- 170
A6 1- 185
A6J1 1- 189
A6P1 1- 186
Page 10010
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

NO. PART NO. FIG. ITEM REQ
AN101006 1- 606 1
AN101006 1 606 1
1 606B 1
AN101008 1 445 1
1 608 1
1 608B 1
AN960C4 3 57 DEL
AN960-C4 1 357 4
3 55A 2
3 110A 2
AN960C6L 1 108A 4
AR11-18 3 80A 1
AR122-06 4 60A 1
4 60D 1
AR19-02 3 120A 2
AR21-02 4 55A 1
AR37-08 3 125A 1
AR48-02 4 60C 1
A52E103KSW 1 411 DEL
1 411B 2
A54E103KSW 1 411A 2
BACC45FN14-12P 1 189 1
BD11-13 1 284 2
3 42 1
B1919 1 495C 2
CA161-01 1 411C 2
CA280-181A 2 170B 2
CA280-821A 1 165B 1
CA288-01 2 130D 3
2 165D 6
CA86-01A 2 170A 2
CA86-02A 1 165C 1
CA92-01 2 175A 3
3 217A 1
CA92-01A 2 175 3
2 175F 3
3 217 1
4 231 1
CA92-11A 2 175B 3
2 175D 3
CC02-06B 1 406B 2
CC02-06N 1 406A 2
CC16-01 5 105A 1
CC34-01 1 406 2
CDIP578040-1C 3 20A 8
CDIP578060-1C 3 20 DEL
CD40193BMJ/883 3 140 2
Page 10011
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

CD4023BMJ/883 3 135 1
CD4024BMJ/883 3 130 1
CD4072BMJ883 3 145 DEL
CD4072BMJL/883 3 145A 1
CEP-16 1 194C 1
CM05-0193BA 3 140A 2
CM05-023BA 3 135A 1
CM05-024BA 3 130A 1
CM05-072BA 3 145B 1
CN63-02 1 189A 1
CN73-02 3 25A 1
4 25A 1
CN73-12 1 186A 1
5 55B 1
CR35-05A 1 495B 2
CR402-5420TX 5 25A 2
DA01-10A 2 45 1
DA01-18A 2 45B 1
DM54LS00J/883C 4 70 1
DM54LS08J/883C 4 75 1
DM54LS221J/883C 4 65 2
DS55325J883 4 80 2
FB02-01 1 187A 6
HA15-02 1 70A 2
JANTXV2N2907A 3 155A 3
4 115A 4
JANTX1N4148-1 3 180 25
3 181 1
4 135 16
4 137 4
4 138 1
JANTX1N4153-1 4 138A 1
4 146 1
4 147 1
JANTX1N4370A 4 140A 1
JANTX1N4370A-1 4 140 1
JANTX1N4972 3 160 1
JANTX1N5420 5 25 2
JANTX1N5614 2 180 6
JANTX1N5617 4 125 6
5 30 2
JANTX1N5807 4 130 4
JANTX1N748A 4 145A 1
JANTX1N748A-1 4 145 1
JANTX1N754A-1 4 150 3
3 175B 2
Page 10012
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

JANTX1N756A-1 3 175 2
3 175C 2
JANTX1N758A-1 3 170 2
JANTX1N825 3 165 2
JANTX1N825-1 3 165A 2
JANTX1N964B-1 4 155B 1
JANTX1N965B 4 155A 1
JANTX1N965B-1 4 155 1
JANTX2N2222A 3 150 6
4 100 6
JANTX2N2369A 4 120 2
JANTX2N2907A 3 155 3
4 115 4
JANTX2N3507 4 85 2
JANTX2N3735 4 90 2
JANTX2N3741 3 45 1
JANTX2N3762 4 95 4
JANTX2N3868 4 95A DEL
JXM19500/483-03 2 45A 1
KT22-13 1 54 2
KT22-16 1 300 12
KT36-02 4 50F 7
LM119H/883 4 55 1
LM124J/883C 3 120 2
LT20-1 4 45A 5
LT20-2 3 10A 1
4 242A 2
LT30-02 1 480 2
LT54-01 3 60 2
LT54-02 1 350 4
3 85 2
LT54-03 1 350A 4
LT54-04 1 350B 4
LT54-05 1 350C 4
LT73-01 3 218A 1
4 233B 1
LT74-01 3 105A 1
LT74-02 3 75A 1
LT74-03 1 335A 2
LU11-1 5 85D 3
MS15795-802 1 191A 4
5 37A 4
MS15795-803 1 55 4
1 87 1
1 191B 4
1 283 5
Page 10013
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

MS15795-803 1 425 4
1 499A 1
1 506 2
1 540 DEL
MS15795-804 1 499 DEL
3 56 DEL
MS15795-805 1 40 11
1 41 2
1 68 8
1 107 4
1 111 2
1 202 1
1 209 3
1 266 3
1 275 8
1 330 4
1 408 1
1 435 3
5 82A 1
5 101 3
5 104 2
MS15795-807 1 80 4
1 545 6
MS15795-808 1 450 2
1 607A 2
MS15795-812 1 130 1
1 142 1
MS15795-814 1 115 1
1 145 1
MS15975-802 5 37 4
MS15975-805 5 82 1
MS15975-808 1 607 DEL
MS20659-130 1 182 2
MS21043-06 2 48 2
MS21266-2N 2 185 AR
MS24693-C2 1 10 7
1 20 7
2 36 3
2 42 2
MS24693-C25 2 26 2
2 32 3
MS24693-C27 1 235 4
2 46A 2
MS24693-C4 1 11 1
1 21 1
MS25036-101 4 470B 1
Page 10014
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

MS25036-102 1 195 3
2 173 2
3 425A 1
4 470A 1
MS25036-103 1 196 2
MS25036-106 1 197 3
MS25036-107 1 387 4
1 537 DEL
1 584 2
MS25082C6 1 143 DEL
MS35338-135 1 88 1
1 192 2
3 35 3
3 35A 2
3 36 DEL
4 35 2
MS35338-136 1 108 2
1 265 4
1 600 1
2 173B 2
5 81 1
5 100 3
5 103 2
MS35338-137 1 85 4
1 541 1
MS35338-138 1 455 1
1 609 1
MS35338-140 1 135 1
1 141 1
MS35338-141 1 120 1
1 144 1
MS35431-1 1 498 1
MS35431-3 3 70 1
MS35431-5 1 345 2
3 70A 1
3 71 DEL
3 95 1
MS35649-244 1 89 1
1 193 2
3 27 1
4 27 1
5 115 1
MS35649-264 1 109 2
1 542 1
1 605 1
MS35650-304 1 460 1
1 610 1
Page 10015
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

MS35650-3314 1 129 1
1 140 1
MS35650-3384 1 114 1
1 143A 1
MS515975-803 1 191 DEL
MS51957-120 4 26 1
MS51957-13 1 155A 2
1 272 1
1 282 5
MS51957-14 1 155 2
1 420 4
1 500 1
2 15 4
MS51957-15 1 50 2
2 136A 12
3 26A 1
3 30 DEL
3 31 1
3 50 DEL
3 116 2
4 26A 1
4 30 1
MS51957-16 1 86 1
3 52 2
3 100 2
MS51957-17 1 190 2
1 365 4
1 385 2
1 507 2
MS51957-18 1 57 1
3 26 1
MS51957-2 5 36 4
MS51957-20 1 395 4
MS51957-21 5 110 1
MS51957-26 2 173C 2
5 80 1
5 95 3
5 102 2
MS51957-27 1 201 1
1 264 4
1 325 4
1 440 3
MS51957-28 1 30 4
1 475 2
MS51957-29 1 67 8
1 407 1
MS51957-3 1 288 4
Page 10016
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

MS51957-30 1 110 2
1 280 8
MS51957-31 1 45 7
1 46 2
1 206 3
1 280A 8
1 538 1
1 585 1
MS51957-32 1 47 3
MS51957-33 1 106 2
MS51957-43 1 550 6
MS51957-45 1 75 4
MS51975-15 2 136 DEL
MS77068-2 5 85 3
5 85B 2
M24693C27 2 46 DEL
M38510/13001BEX 4 80C 2
M38527/02-038D 4 15 8
M38527/03-002D 3 15A 9
3 15B 9
4 10A 12
4 10C 12
M38527/3-02D 3 15 9
3 15C 9
4 10 12
4 10B 12
M39003/01-1529 4 525 1
M39003/01-2257 4 170 1
M39003/01-2306 4 165 1
M39003/01-2523 4 175 3
M39003/01-2977 4 510 1
M39014/01-1302 4 230 1
M39014/01-1305 4 225 6
M39014/01-1314 4 195A 1
M39014/01-1317 3 430 1
4 215 2
4 217 1
M39014/01-1320 4 210 2
4 232 1
M39014/01-1523 4 159 2
M39014/01-1526 4 205 2
M39014/01-1529 4 525A 1
M39014/01-1535 3 215 4
3 216 1
4 184A 1
4 186 1
4 187 1
4 200 1
Page 10017
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

M39014/01-1541 4 195 1
4 220 1
M39014/01-1553 3 210 14
4 187A 1
4 188 2
5 15 2
M39014/02-1289 1 525 2
M39014/02-1310 3 205 1
M39014/02-1318 4 190A 1
M39014/02-1320 3 194 1
M39014/02-1358 3 196A 1
3 200 1
4 190 1
M39014/02-1360 3 194A 1
M39014/02-1413 4 184 1
4 185 2
M39014/02-1415 1 170 2
3 195 4
3 196 1
4 180 1
4 182 1
M39014/02-1419 1 170A 2
M39018/01-0740 3 190 1
M55302/62-A20S 1 186 1
5 55 1
M556DC883B 3 125 1
M83421/01-0192M 1 501 1
M83421/01-4299S 2 130C 3
2 165C 6
M83421/01-4300M 2 130B 3
2 165B 6
M83421/01-4300S 2 130A 3
2 165A 6
M83421/01-6088P 4 160 1
M83421/01-6171M 3 185 1
M83421/01-9300M 2 130 3
2 165 6
M83723/60-214AN 1 194 1
1 194D 1
NAS1397P5B 1 406E 2
NAS1397P5N 1 406D 2
NAS1801-3-6 1 606A 1
NAS1801-3-8 1 445A 1
1 608A 1
NAS620C2 1 287 4
NAS620C4L 1 150 2
1 273 1
Page 10018
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

NAS620C4L 1 295 12
1 375 2
1 400 4
2 20 4
2 138 12
3 40 4
3 40A 2
3 41 DEL
3 55 2
3 110 2
3 117 2
4 40 2
NAS620C5 1 357A 4
NAS620C5L 1 357B 4
NAS620C6L 1 267 1
1 476 2
1 539 1
1 590 1
1 595 1
2 47 2
2 173A 2
3 65 1
NAS620C8L 1 360 2
3 90 1
NAS622-T2 1 230 2
PC04-01 1 200 1
PC28-25 1 194A 1
1 194B 1
PLC1M-S4 5 105 1
PN11-18 3 470A 7
PR32-62 3 475 9
RC-CS280075-1C 4 233 1
RC-CS280075-1V 3 218 1
4 233A 1
RCDIP578040-1C 4 20 7
4 20B 7
RCDIP578060-1C 4 20A 7
RCR07G100JS 3 345 1
3 345B 1
RCR07G101JS 3 350 1
3 350B 1
3 350E 1
RCR07G102JS 3 320 3
3 320B 3
4 340 1
4 341 2
4 341B 2
Page 10019
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

4 341D 2
RCR07G102JS 4 341F 2
4 520A 1
RCR07G103JS 3 340 12
3 340B 12
4 335 4
4 335B 4
4 335D 4
4 336 1
4 336C 1
RCR07G104FS 3 360A 4
3 360 4
RCR07G104JS 3 360C 4
3 361 1
3 361B 1
3 362 1
4 365 1
4 365B 1
RCR07G105JS 3 355 2
3 355B 2
4 345 1
RCR07G106JS 3 405 2
3 405E 2
3 405G 2
3 405J 2
RCR07G1212FS 3 330B 1
RCR07G122JS 4 395 1
4 395B 1
4 395D 1
RCR07G123JS 3 330 1
3 330C 1
3 330E 1
RCR07G124JS 3 335 1
4 325 1
RCR07G134JS 4 325B 1
4 325D 1
RCR07G152JS 3 375 2
3 375A DEL
3 375C 2
3 377 1
3 377B 1
RCR07G153JS 3 315 2
3 315B 2
3 316 1
3 317 1
RCR07G154JS 3 395 2
3 395B 2
Page 10020
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

RCR07G155JS 3 410 1
3 410B 1
RCR07G180JS 4 315 2
4 315B 2
4 315D 2
RCR07G181JS 4 385 2
4 385B 2
4 385D 2
4 386 1
4 386C 1
RCR07G221JS 4 310 2
4 310B 2
4 310D 2
RCR07G222JS 3 310 2
3 310B 2
4 290 2
4 290B 2
4 290D 2
RCR07G223JS 3 325 1
3 326 1
3 326B 1
3 327 1
4 405 2
4 405B 2
4 405D 2
4 406 1
4 406C 1
RCR07G224JS 3 335C 1
3 390 1
3 390B 1
3 390D 1
RCR07G272JS 3 365 1
3 365B 1
4 330 2
4 330D 2
4 330F 2
4 455C 1
4 455E 1
RCR07G274JS 3 370 1
3 370B 1
RCR07G2R7JS 5 10 2
RCR07G330JS 4 300 2
4 300B 2
4 300D 2
RCR07G332JS 4 350 2
4 350B 2
Page 10021
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

4 350D 2
RCR07G333JS 3 362C 1
3 380C 1
3 420 2
3 420B 2
3 420D 2
RCR07G361JS 4 280 2
4 280B 2
4 280D 2
RCR07G393JS 4 360 1
4 360B 1
4 360D 1
RCR07G471JS 4 337A 1
4 337C 1
4 355 7
4 355A 7
4 355D 7
4 530A 1
4 530C 1
RCR07G472JS 4 380 2
4 380B 2
4 380D 2
RCR07G473JS 3 400 4
3 400E 4
3 400G 4
3 401 1
3 402 DEL
4 375 1
4 375B 1
4 375D 1
4 480A 1
4 480C 1
RCR07G560JS 4 305 2
4 305B 2
4 305D 2
RCR07G561JS 4 320 2
4 320B 2
4 320D 2
RCR07G563JS 4 285 1
4 285B 1
4 285D 1
RCR07G565JS 4 410 1
4 410C 1
RCR07G681JS 3 415 1
RCR07G683JS 3 380 1
4 370 2
4 370B 2
Page 10022
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

4 370D 2
RCR07G8R2JS 4 390 2
4 390B 2
4 390D 2
4 390F 2
4 390J 2
RCR07G820JS 4 295 2
4 295B 2
4 295D 2
RCR07G823JS 4 400 1
RCR20G102JS 3 305 1
3 305B 1
RCR20G104JS 2 155 2
2 155D 2
RCR20G330JS 4 270 2
4 270B 2
RCR20G8R2JS 4 275 2
4 275B 2
RCR42G100JS 1 530 2
RCR42G221JS 2 160 1
RCR42G391JS 4 260 2
RCR42G471JS 4 255 2
RCR42G560JS 4 265 1
RER60F4R99R 4 235 2
RER75F6R04R 1 415 2
RLR07C1000FS 3 350A 1
3 350F 1
RLR07C1000GS 4 515 1
RLR07C1001FS 3 320A 3
4 341C 2
4 341E 2
RLR07C1001GS 4 341A 2
4 520 1
RLR07C1002FS 3 340A 12
4 335C 4
4 336B 1
RLR07C1002GS 4 335A 4
RLR07C1003FS 3 360B 4
3 361C 1
4 365A 1
RLR07C1004FS 3 355A 2
RLR07C1005FP 3 405D 2
RLR07C1005FR 3 405C 2
3 405F 2
RLR07C1005FS 3 405A 2
3 405B 2
3 405H 2
Page 10023
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

RLR07C10R0FS 3 345A 1
4 390C 2
RLR07C10R0GS 3 415A 1
4 390A 2
4 535 1
RLR07C1201GS 4 395A 1
4 395C 1
RLR07C1202GS 3 330A 1
3 330D 1
RLR07C1501FS 3 375B 2
3 377A 1
RLR07C1502FS 3 315A 2
3 317A 1
RLR07C1503FS 3 395A 2
RLR07C1504FS 3 410A 1
RLR07C1601GS 4 336A 1
RLR07C1601GS 4 337 1
RLR07C1800GS 4 385A 2
4 385C 2
4 386B 1
RLR07C18R0GS 4 315A 2
4 315C 2
RLR07C20R0FR 3 350C 1
RLR07C20R0FS 3 350D 1
RLR07C2200GS 4 310A 2
RLR07C2200GS 4 310C 2
RLR07C2201GS 3 310A 2
4 290A 2
4 290C 2
RLR07C2202GS 3 326A 1
4 405A 2
4 405C 2
4 406B 1
RLR07C2203GS 3 335A 1
3 335B 1
3 390C 1
RLR07C2213FS 3 390A 1
RLR07C27R0GS 3 350G 1
RLR07C2701GR 4 330B 2
4 455A 1
RLR07C2701GS 3 365A 1
4 330A 2
4 330C 2
4 330E 2
4 455 1
4 455B 1
Page 10024
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

4 455D 1
RLR07C2702GR 3 300 1
RLR07C2703GS 3 370A 1
RLR07C33R0GS 4 300A 2
4 300C 2
RLR07C3300GS 4 406A 1
RLR07C3301GS 4 350A 2
4 350C 2
RLR07C3302GS 3 362A 1
3 362B 1
3 380A 1
3 380B 1
3 381 DEL
3 420C 2
RLR07C3322FS 3 420A 2
RLR07C3902GS 4 360A 1
4 360C 1
RLR07C4301GS 3 316A 1
3 440 DEL
RLR07C4700GS 4 337B 1
4 355B 7
4 355C 7
4 530B 1
RLR07C4701GS 4 380A 2
4 380C 2
RLR07C4702GS 3 400C 4
3 400F 4
4 375A 1
4 375C 1
4 480 1
4 480B 1
RLR07C4752FS 3 400D 4
RLR07C5101GS 3 302 1
RLR07C56R0GS 4 305A 2
4 305C 2
RLR07C5600GS 4 320A 2
4 320C 2
RLR07C5602GS 4 285A 1
4 285C 1
RLR07C5604GR 4 410B 1
RLR07C5604GS 4 410A 1
RLR07C6200GS 4 530 1
RLR07C6802GS 4 370A 2
4 370C 2
RLR07C8R20GM 4 390E 2
RLR07C8R20GS 4 390G 2
4 390H 2
Page 10025
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

RLR07C82R0GS 4 295A 2
4 295C 2
RLR07C8202GR 4 400A 1
4 475 1
RLR07C8202GS 4 400B 1
4 475A 1
RLR07G1303FS 4 325C 1
RLR07G1303GS 4 325A 1
RLR07G3302GS 3 361A DEL
RLR07G3600GS 4 280A 2
4 280C 2
RLR20C1001FS 3 305A 1
RLR20C1003FS 2 155A 2
RLR20C1003GS 2 155B 2
2 155C 2
RLR20C2401GS 3 376 1
RLR20C33R0GS 4 270A 2
RLR20C8R20GS 4 275A 2
RNC55H1001BS 4 450 1
4 450D 1
RNC55H1001FS 4 450A 1
4 450C 1
RNC55H1002BS 3 327A 1
3 327D 1
4 105K 1
RNC55H1002FS 3 327B 1
3 327C 1
4 105L 1
RNC55H1102BS 4 105H 1
4 430K 1
RNC55H1102FS 4 105J 1
4 430L 1
4 440B 1
RNC55H1152FS 4 440C 1
RNC55H1211FS 3 290 2
RNC55H1242FS 4 485 1
RNC55H1622FS 4 250B 1
RNC55H1652FS 4 430F 1
RNC55H1741FS 4 430 1
RNC55H2001FS 3 287A 1
RNC55H2152FS 3 240 1
RNC55H2252BS 3 400A DEL
RNC55H2552BS 3 401B 1
RNC55H2552FS 3 400B DEL
3 401A 1
RNC55H2611FS 3 285 1
3 287 1
Page 10026
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

4 250 1
RNC55H2642BS 3 235A 1
RNC55H2642FS 3 235C 1
RNC55H2671BS 3 230A 3
3 230C 3
RNC55H2671FS 3 230 3
3 230B DEL
3 230D 3
RNC55H2672FS 3 235 1
3 235B 1
RNC55H2740FS 4 445 1
RNC55H2742FS 3 265 1
RNC55H2872BS 3 250A 2
3 250D 2
RNC55H2872FS 3 250 2
3 250B DEL
3 250C 2
RNC55H3013FS 3 435 1
RNC55H3161FS 3 255 1
RNC55H33R2FS 4 425 1
RNC55H3902BS 4 465 DEL

RNC55H3902FS 4 465A DEL
RNC55H4120FS 4 445A 1
RNC55H4122BS 4 460D 1
RNC55H4122FS 4 460E 1
RNC55H4221BS 3 280C 1
RNC55H4221FS 3 280D 1
RNC55H4421FS 3 275 1
RNC55H4531BS 4 430H 1
RNC55H4531FS 4 430J 1
RNC55H4641BS 3 260A 3
3 260D 3
4 430A DEL
4 430E DEL
RNC55H4641FS 3 260 3
3 260B DEL
3 260C 3
4 420 1
4 430B DEL
4 450E 1
RNC55H4750FS 4 435 1
RNC55H4752FS 4 386A 1
RNC55H4871FS 4 440 1
RNC55H4992FS 3 270A 1
RNC55H5111BS 4 430C 1
RNC55H5111FS 4 430D 1
RNC55H5231BS 3 280A 1
Page 10027
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

RNC55H5231FS 3 280B 1
RNC55H5361FS 3 296 1
RNC55H5622FS 3 270 1
RNC55H5761FS 3 245 1
4 460A DEL
RNC55H59R0BS 4 110 1
RNC55H59R0FS 4 110A 1
RNC55H6043BS 3 296A 1
RNC55H6043FS 3 296C 1
RNC55H6191BS 3 295C 1
RNC55H6191FS 3 295D 1
RNC55H6193BS 4 460F 1
4 465F 1
RNC55H6193FS 3 296B 1
4 460G 1
4 465G 1
RNC55H6203BS 4 460B DEL
4 465B DEL
RNC55H6203FS 4 460C DEL
4 465C DEL
RNC55H6491BS 4 465D 1
RNC55H6491FS 4 465E 1
RNC55H6652BS 3 300A 1
3 300D 1
RNC55H6652FS 3 300B 1
3 300C 1
RNC55H6811BS 3 275A 1
3 275F 1
RNC55H6811FS 3 275B 1
3 275E 1
RNC55H71R5BS 4 110B 1
4 425A 1
RNC55H71R5FS 4 110C 1
4 425B 1
RNC55H7151BS 3 295A 1
RNC55H7151FS 3 295 1
3 295B DEL
3 295E 1
RNC55H7681FS 3 280 1
4 415 2
4 450B DEL
RNC55H7682FS 4 430G 1
RNC55H7871BS 3 275C 1
RNC55H7871FS 3 275D 1
RNC55H8061BS 4 105F 1
RNC55H8061FS 4 105G 1
RNC55H8871FS 4 250A 1
Page 10028
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

RNC55H9091BS 4 105D 1
RNC55H9091FS 4 105E 1
4 105B DEL
RNC55H9311FS 4 105A DEL
4 105C DEL
RNC55H9531FS 4 440A 1
RNC60H2674BS 3 385A 1
3 385C 1
RNC60H2674FM 3 385E 1
3 385G 1
RNC60H2674FS 3 385 1
3 385B DEL
3 385D DEL
3 385F 1
3 385H 1
RWR80N2210FR 2 160A 1
RWR81S3830FR 3 225 1
RWR81S5230FR 4 240 2
RWR81S6R81FR 4 245 1
RWR89S1R00FR 3 220 1
SC01-01 4 50C 7
4 50E 7
SER1089H 1 495D 2
SE556JB 3 125B 1
SG140-12K/883B 3 80 1
SG1524J883B 4 60 1
SG55325J/883 4 80A 2
SJ6774H4 1 340 DEL
SJ6774H6 1 340A DEL
SN54LS00JBCBJC 4 70C 1
SN54LS00JSNJ 4 70B 1
SP73205-177 3 58 DEL
SSP-73205-177PH 1 346 4
3 58A 2
3 101 2
SSP83705-177 1 107A 4
STD111-8 3 28 1
4 28B 1
TD36-01 1 175B 2
TE12-1 3 425B 1
4 470C 1
TE22-02 1 535 1
Page 10029
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

TE47-01 1 412 1
1 497 1
TF50-197-01 2 25A 1
TF50-277-01 5 40 2
TF50-312-01 1 544 1
TF50-313-01 2 30 1
TF50-315-01 2 25 1
TF50-317-01 2 40 1
TF50-317-02 2 40A 1
TF50-321-01 1 430 1
TF50-361-01 2 35 1
TF50-362-01 5 35 2
TF50-366-01 1 370 1
TF50-720-01 1 370A 1
TL11-00B 4 70A 1
TL11-08B 4 75A 1
TL11-221B 4 65A 2
TM13-02 3 485A 7
TM14-02 3 480A 6
TM15-01 2 150A 5
TM16-18T 4 495B 1
TM40-02 5 20A 2
TP09-03 3 20B 8
4 20C 7
TP13-01 4 15B 8
TR50-02A 1 340C 2
TR50-03A 1 340B 2
TR50-03AM 1 340D 2
TX22/14/6.4-3E27 1 175A 2
UF02-02 4 80B 2
URZA457 2 170C 2
URZA715 1 165A 1
UTG5140 1 495 2
UTG8187 1 495A 2
WA25-01 1 346A 4
3 58B 2
3 101A 2
WA25-03 1 107B 4
WA28-02 4 42 1
WTAX20SECJTA 5 55A 1
WTB20PR7J548 3 25 1
4 25 1
0314-0-15-15-34-26-10-0 4 50B 7
4 50D 7
09-8061-2-035 3 470 7
09-9002-1-03 4 50A 7
10-301-2-05 3 485 7
Page 10030
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

10-753-3-05 2 150 5
10-805-2-05 3 480 6
10-915-3-04 4 495 1
10-915-3-05 4 495A 1
10099DAP 4 15A DEL
102H46W103KQ3H 2 175E 3
10352A0832-2 1 70 2
10459DAP 4 45 5
11A 4 28 1
11A120 3 28A 1
4 28A 1
1127-41-05-16 1 412A 1
1 497A 1
1299B-5 5 20 2
135 1 535A 1
151B103K501LEXH 2 175C 3
3 217B 1
4 231A 1
1902 5 85A 3
5 85C 2
2-36151-2 3 425 1
4 470 1
2673021801 1 187 6
380635-3 4 50 DEL
4-254-02 1 1 RF
4-254-03 1 1A RF
4-254-04 1 1B RF
4-254205-01 2 135 1
2 135B 1
4-254205-02 2 135A 1
4-254207-01 2 10 1
4-254217-01 1 305A 1
4-254226-01 1 505 1
4-254228-01 1 105A 1
4-254235-01 1 25 1
4-254240-01 1 225 2
4-254241-01 3 115 1
4-254242-01 1 465 1
4-254253-01 1 290 1
3 1 RF
4-254253-02 1 290A 1
3 1A RF
4-254253-03 1 290G 1
3 1G RF
4-254253-04 1 290H 1
3 1H RF
Page 10031
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

4-254255-01 1 285 1
4 1 RF
4-254255-02 1 285A 1
4 1A RF
4-254260-01 4 500 1
4-254301-01 1 35 1
1 35B 1
2 1 RF
4-254301-02 1 35A 1
2 1A RF
4-254302-01 2 5 1
4-254303-01 2 115 1
4-254304-01 2 128 1
4-254309-01 1 310 1
4-254310-01 1 315 1
4-254311-01 1 390A DEL
5 1A RF
4-254311-01-900 5 120A 1
4-254315-01 1 320 2
4-254316-01 1 270 DEL
1 270F 1
4-254316-02 1 270C 1
4-254317-01 1 305 1
4-254322-01 1 405 1
4-254323-01 1 410 1
4-254324-01 1 470 1
4-254325-01 1 490 1
4-254328-01 1 105 1
4-254329-01 1 146 1
4-254330-01 1 160 1
4-254334-01 1 185 1
4-254336-01 1 65 1
1 65E 1
4-254337-01 1 5 1
4-254338-01 1 15 1
4-254339-01 1 205 1
4-254343-01 1 281 1
4-254353-01 1 290B 1
3 1B RF
4-254353-02 1 290C 1
3 1C RF
4-254353-03 1 290J 1
3 1J RF
4-254353-04 1 290K 1
3 1K RF
4-254409-01 1 310A 1
4-254410-01 1 315A 1
Page 10032
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

4-254411-01 1 390 DEL

5 1 RF
4-254411-01-900 5 120 1
4-254411-02 1 390C 1
5 1C RF
4-254411-02-900 5 120B 1
4-254416-01 1 270B 1
4-254416-02 1 270E 1
4-254417-01 1 305B 1
4-254423-01 1 410A 1
4-254436-01 1 65A 1
1 65D 1
4-254453-01 1 290E 1
3 1E RF
4-254453-02 1 290F 1
3 1F RF
4-254453-03 1 290M 1
3 1M RF
4-254453-04 1 290N 1
3 1N RF
4-254455-01 1 285C 1
4 1B RF
4-254511-01 1 390B 1
5 1B RF
4-254516-01 1 270A 1
4-254516-02 1 270D 1
4-254517-01 1 305C 1
4-254536-01 1 65B 1
4-254536-02 1 65C 1
4-254553-01 1 290D 1
3 1D RF
4-254553-02 1 290L 1
3 1L RF
4-254555-01 1 285B 1
4 1C RF
4-254655-01 1 285E 1
4 1D RF
4-254655-02 1 285F 1
4 1E RF
4-254655-03 1 285G 1
4 1F RF
4-254755-01 1 285D 1
4 1G RF
4-273214-01 1 137 1
526700-02 3 10 1
4 242 2
Page 10033
24-31-04 May 25/12
4-254
NUMERICAL INDEX
PART AIRLINE TTL

5962-8764501EX 4 60B 1
4 60E 1
673D311 1 165 DEL
673D312A 2 170 2
69-11-B522-1678 3 105 1
69-11-B523-1678 3 75 1
69-11-B577-1678 1 335 2
770-1604 1 406F 2
846XT250-3E2A 1 175 2
8958 1 406C 2
Page 10034
24-31-04 May 25/12
4-254
IPL Figure 1 (Sheet 1 of 6)

Battery Charger Assembly
Page 10035
24-31-04 May 25/12
4-254

Page 10036
24-31-04 May 25/12
4-254

Page 10037
24-31-04 May 25/12
4-254

Page 10038
24-31-04 May 25/12
4-254

Page 10039
24-31-04 May 25/12
4-254
IPL Figure 1 (Sheet 6)

Page 10040
24-31-04 May 25/12
4-254
UNITS
FIG AIRLINE NOMENCLATURE EFFECT PER
ITEM PART NUMBER PART NO. 1234567 CODE ASSY
1–
-1 4-254-02 BATTERY CHARGER (V08748) A RF
(PRE SB4-254-24-09)
(PRE SB4-254-24-10)
(BOEING PN S282T002-2)
BATTERY CHARGER (MOD 1) (V08748) B RF
(POST SB4-254-24-10)
-1A 4-254-03 BATTERY CHARGER (V08748) C RF
(POST SB4-254-24-09)
(PRE SB4-254-24-10)
-1B 4-254-04 BATTERY CHARGER (V08748) D RF
(POST SB4-254-24-10)
5 4-254337-01 . COVER, TOP (V08748) 1
ATTACHING PARTS
10 MS24693C2 . SCREW 7
(CORRECT PN IS MS24693-C2)
11 MS24693C4 . SCREW 1
***
15 4-254338-01 . COVER, BOTTOM (V08748) 1
ATTACHING PARTS
20 MS24693C2 . SCREW 7
21 MS24693C4 . SCREW 1
***
25 4-254235-01 . MOUNTING STRAP (V08748) 1
ATTACHING PARTS
30 MS51957-28 . SCREW 4
***
35 4-254301-01 . INPUT ASSY, A1 (V08748) A, B, C 1
(SEE FIGURE 2 FOR DETAIL BKDN)
-35A 4-254301-02 . INPUT ASSY, A1 (V08748) D 1
-35B 4-254301-01 . INPUT ASSY, A1 (V08748) (OPTIONAL) D
ATTACHING PARTS
40 MS15795-805 . WASHER, FLAT 11
-41 MS15795-805 . WASHER, FLAT 2
- Item not illustrated

Page 10041
24-31-04 May 25/12
4-254
UNITS
1–
45 MS51957-31 . SCREW 7
-46 MS51957-31 . SCREW 2
47 MS51957-32 . SCREW 3
50 MS51957-15 . SCREW 2
54 KT22-13 . SCREW (V08748) 2
55 MS15795-803 . WASHER, FLAT 4
57 MS51957-18 . SCREW 1
***
65 4-254336-01 . PANEL, FRONT (V08748) A, B 1
-65A 4-254436-01 . PANEL, FRONT (V08748) C 1
(REPLS ITEM 65E)
-65B 4-254536-01 . PANEL, FRONT (V08748) D
(OPTIONAL)
-65C 4-254536-02 . PANEL, FRONT (V08748) D 1
(REPLS ITEM 65D)
-65D 4-254436-01 . PANEL, FRONT (V08748) D
(REPLD BY ITEM 65C)
-65E 4-254336-01 . PANEL, FRONT (V08748) C
(REPLD BY ITEM 65A)
ATTACHING PARTS
67 MS51957-29 . SCREW 8
68 MS15795-805 . WASHER, FLAT 8
***
70 10352A0832-2 . HANDLE (V06540) (HA15-02, V08748) 2
(CORRECT PN IS 10352-A-0832-2)
-70A HA15-02 . HANDLE (V08748) (OPTIONAL)
ATTACHING PARTS
75 MS51957-45 . SCREW 2
80 MS15795-807 . WASHER, FLAT 2
85 MS35338-137 . WASHER, LOCK 2
***
86 MS51957-16 . SCREW 1
87 MS15795-803 . WASHER, FLAT 1
88 MS35338-135 . WASHER, LOCK 1
89 MS35649-244 . NUT 1

Page 10042
24-31-04 May 25/12
4-254
UNITS
1–
105 4-254328-01 . TERMINAL BLOCK ASSY, A5 (V08748) 1
-105A 4-254228-01 . TERMINAL BLOCK ASSY, A5 (V08748)
(OPTIONAL)
ATTACHING PARTS
106 MS51957-33 . SCREW 2
107 MS15795-805 . WASHER, FLAT A, B 4
-107A SSP83705-177 . WASHER, BELLEVILLE (V02368) C, D 4
(WA25-03, V08748)
-107B WA25-03 . WASHER, BELLEVILLE (V08748)
(OPTIONAL)
108 MS35338-136 . WASHER, LOCK A, B 2
-108A AN960C6L . WASHER, FLAT C, D 4
109 MS35649-264 . NUT 2
110 MS51957-30 . SCREW 2
111 MS15795-805 . WASHER, FLAT 2
***
114 MS35650-3384 . . NUT, MACH 1
115 MS15795-814 . . WASHER, FLAT 1
120 MS35338-141 . . WASHER, LOCK 1
129 MS35650-3314 . . NUT, MACH 1

130 MS15795-812 . . WASHER, FLAT 1
135 MS35338-140 . . WASHER, LOCK 1
137 4-273214-01 . . TERMINAL BLOCK (V08748) 1
ATTACHING PARTS
140 MS35650-3314 . . NUT, MACH 1
141 MS35338-140 . . WASHER, LOCK 1
142 MS15795-812 . . WASHER, FLAT 1
143 MS25082C6 DELETED
-143A MS35650-3384 . . NUT, MACH 1
144 MS35338-141 . . WASHER, LOCK 1
145 MS15795-814 . . WASHER, FLAT 1
***
146 4-254329-01 . . COVER, COMPONENT (V08748) 1
ATTACHING PARTS
150 NAS620C4L . . WASHER, FLAT 2
155 MS51957-14 . . SCREW 2
(REPLS ITEM 155A)
-155A MS51957-13 . . SCREW
(REPLD BY ITEM 155)
***

Page 10043
24-31-04 May 25/12
4-254
UNITS
1–
160 4-254330-01 . . FILTER, CAP ASSY, A5A1 (V08748) 1
165 673D311 DELETED
-165A URZA715 . . . CAP, 820 F, 50 VDC, +100/-10% 1
(V7M138) (V08748, CA280-821A)
(SUPSDS 165)
(REPLS ITEM 165C)
-165B CA280-821A . . . CAP, 820 F, 50 VDC, +100/-10%
(V08748) (OPTIONAL)
-165C CA86-02A . . . CAP, 820 F, 50 VDC, +100/-10%
(V08748) (REPLD BY ITEM 165A)
170 M39014-02-1415 . . . CAP, 50 VDC, 1 F, 10% 2
(CORRECT PN IS M39014/02-1415)
-170A M39014-02-1419 . . . CAP, 50 VDC, 1 F, 10% (OPTIONAL)
175 846XT250-3E2A . . . CORE, TOROID (V02114)
(TD36-01, V08748)
(SUPSD BY ITEM 175A)
-175A REF01 . . . CORE, TOROID (V3RMR9) 2
(TD36-01, V08748)
(CORRECT PN IS TX22/14/6.4-3E27)
(SUPSDS ITEM175)
-175B TD36-01 . . . CORE, TOROID (V08748) (OPTIONAL)
182 MS20659-130 . . . LUG, CRIMP 2
185 4-254334-01 . HARNESS, INPUT, A6 (V08748) 1
186 M55302-62A20S . . CONNECTOR 1
(CORRECT PN IS M55302/62-A20S)
-186A CN73-12 . . CONNECTOR (V08748) (OPTIONAL)
-187 2673021801 . . BEAD, SHIELD (V34899) 6
(FB02-01, V08748)
-187A FB02-01 . . BEAD, SHIELD (V08748) (OPTIONAL)
189 BACC45FN14-12P . . CONNECTOR (V02660) 1
(CN63-02, V08748)
-189A CN63-02 . . CONNECTOR (V08748) (OPTIONAL)
ATTACHING PARTS
190 MS51957-17 . SCREW 2
191 MS515975-803 DELETED
-191A MS15795-802 . WASHER, FLAT
(SUPSD BY ITEM 191B)
-191B MS15795-803 . WASHER, FLAT 4
(SUPSDS ITEM 191A)
192 MS35338-135 . WASHER, LOCK 2
193 MS35649-244 . NUT 2
***

Page 10044
24-31-04 May 25/12
4-254
UNITS
1–
194 M83723-60-214AN . COVER, CONNECTOR A-C 1
(CORRECT PN IS M83723/60-214AN)
-194A PC28-25 . COVER, CONDUCTIVE (V08740) A-C
(OPTIONAL)
-194B PC28-25 . COVER, CONDUCTIVE (V08740) D 1
-194C CEP16 . COVER, CONDUCTIVE (V99017) D
(PC28-25, V08748) (OPTIONAL)
(CORRECT PN IS CEP-16)
-194D M83723-60-214AN . COVER, CONNECTOR (OPTIONAL) D
(CORRECT PN IS M83723/60-214AN)
195 MS25036-102 . LUG 3
196 MS25036-103 . LUG 2
197 MS25036-106 . LUG 3
200 PC04-01 . COVER, PROTECTION (V08748) 1
ATTACHING PARTS
201 MS51957-27 . SCREW 1
202 MS15795-805 . WASHER, FLAT 1
***
205 4-254339-01 . HEAT SHIELD (V08748) 1
ATTACHING PARTS
206 MS51957-31 . SCREW 3
209 MS15795-805 . WASHER, FLAT 3
***
225 4-254240-01 . INSULATOR (V08748) 2
230 NAS622T2 . BRACKET, FRONT SUPPORT 2
(CORRECT PN IS NAS622-T2)
ATTACHING PARTS
235 MS24693C27 . SCREW 2
***
264 MS51957-27 . SCREW 4
265 MS35338-136 . WASHER, LOCK 4
266 MS15795-805 . WASHER, FLAT 3
267 NAS620C6L . WASHER, FLAT 1
270 4-254316-01 . DELETED
-270A 4-254516-01 . HEAT SINK ASSY, REAR, A3 (V08748) C 1
-270B 4-254416-01 . HEAT SINK ASSY, REAR, A3 (V08748) C
(OPTIONAL)
-270C 4-254316-02 . HEAT SINK ASSY, REAR, A3 (V08748) A, B 1
(POST SB4-254-24-10)
(REPLS ITEM 270F)

Page 10045
24-31-04 May 25/12
4-254
UNITS
1–
-270D 4-254516-02 . HEAT SINK ASSY, REAR, A3 (V08748) D 1
(POST SB4-254-24-10)
-270E 4-254416-02 . HEAT SINK ASSY, REAR, A3 (V08748) D
(OPTIONAL) (POST SB4-254-24-10)
-270F 4-254316-01 . HEAT SINK ASSY, REAR, A3 (V08748) A
(REPLD BY ITEM 270C)
ATTACHING PARTS
272 MS51957-13 . SCREW 1
275 MS15795-805 . WASHER, FLAT 8
280 MS51957-30 . SCREW
-280A MS51957-31 . SCREW 8
(SUPSDS ITEM 280)
***
281 4-254343-01 . . COVER, REAR (V08748) 1
ATTACHING PARTS
282 MS51957-13 . . SCREW 5
283 MS15795-803 . . WASHER, FLAT 5
***
284 BD11-13 . . INSULATOR (V08748) 2
285 4-254255-01 . . CIRCUIT CARD ASSY, A3A2 (V08748) A, B
-285A 4-254255-02 . . CIRCUIT CARD ASSY, A3A2 (V08748) A, B
-285B 4-254555-01 . . CIRCUIT CARD ASSY, A3A2 (V08748) A, B 1
(SUPSDS ITEMS 285 AND 285A)
-285C 4-254455-01 . . CIRCUIT CARD ASSY, A3A2 (V08748) A, B
(OPTIONAL)
-285D 4-254755-01 . . CIRCUIT CARD ASSY, A3A2 (V08748) C, D 1
-285E 4-254655-01 . . CIRCUIT CARD ASSY, A3A2 (V08748) C, D

Page 10046
24-31-04 May 25/12
4-254
UNITS
1–
-285F 4-254655-02 . . CIRCUIT CARD ASSY, A3A2 (V08748) C, D
-285G 4-254655-03 . . CIRCUIT CARD ASSY, A3A2 (V08748) C, D
287 NAS620C2 . . WASHER, FLAT 4
288 MS51957-3 . . SCREW 4
290 4-254253-01 . . CIRCUIT CARD ASSY, A3A1 (V08748) A
(SUPSD BY ITEM 290C)
-290A 4-254253-02 . . CIRCUIT CARD ASSY, A3A1 (V08748) A
-290B 4-254353-01 . . CIRCUIT CARD ASSY, A3A1 (V08748) A
-290C 4-254353-02 . . CIRCUIT CARD ASSY, A3A1 (V08748) A 1
(SUPSDS ITEMS 290, 290A,
AND 290B)

-290D 4-254553-01 . . CIRCUIT CARD ASSY, A3A1 (V08748) C 1
-290E 4-254453-01 . . CIRCUIT CARD ASSY, A3A1 (V08748) C
-290F 4-254453-02 . . CIRCUIT CARD ASSY, A3A1 (V08748) C
-290G 4-254253-03 . . CIRCUIT CARD ASSY, A3A1 (V08748) B
(POST SB4-254-24-10)
(SUPSD BY ITEM 290 K)
-290H 4-254253-04 . . CIRCUIT CARD ASSY, A3A1 (V08748) B
(POST SB4-254-24-10)
-290J 4-254353-03 . . CIRCUIT CARD ASSY, A3A1 (V08748) B
(POST SB4-254-24-10)

Page 10047
24-31-04 May 25/12
4-254
UNITS
1–
-290K 4-254353-04 . . CIRCUIT CARD ASSY, A3A1 (V08748) B 1
(POST SB4-254-24-10)
(SUPSDS ITEMS 290G, 290H,
AND 290J)
-290L 4-254553-02 . . CIRCUIT CARD ASSY, A3A1 (V08748) D 1
(POST SB4-254-24-10)
-290M 4-254453-03 . . CIRCUIT CARD ASSY, A3A1(V08748) D
(OPTIONAL)
(POST SB4-254-24-10)
-290N 4-254453-04 . . CIRCUIT CARD ASSY, A3A1 (V08748) D
(OPTIONAL)
(POST SB4-254-24-10)
ATTACHING PARTS
300 KT22-16 . . SCREW (V08748) 12
***
305 4-254317-01 . . HEAT SINK, REAR (V08748) A, B 1

-305A 4-254217-01 . . HEAT SINK, REAR (V08748) A, B
(OPTIONAL)
-305B 4-254417-01 . . HEAT SINK, REAR (V08748) C, D
-305C 4-254517-01 . . HEAT SINK, REAR (V08748) C, D 1
(SUPSDS ITEM 305B)
310 4-254309-01 . HEAT SINK ASSY, RIGHT, A2 (V08748)
-310A 4-254409-01 . HEAT SINK ASSY, RIGHT, A2 (V08748) 1
(SUPSDS ITEM 310)
315 4-254310-01 . . HEAT SINK, RIGHT (V08748) 1
-315A 4-254410-01 . . HEAT SINK, RIGHT (V08748)
(OPTIONAL)
320 4-254315-01 . . COVER, TRANSISTOR (V08748) 2
ATTACHING PARTS
325 MS51957-27 . . SCREW 2
330 MS15795-805 . . WASHER, FLAT 2
***
335 69-11B577-1678 . . INSULATOR (V18565) 2
(LT74-03, V08748)
(CORRECT PN IS 69-11-B577-1678)
-335A LT74-03 . . INSULATOR (V08748) (OPTIONAL)

Page 10048
24-31-04 May 25/12
4-254
UNITS
1–
340 SJ6774H4 DELETED
-340A SJ6774H6 DELETED
-340B TR50-03A . . SEMICOND, XSTR (V08748)
(REPLD BY ITEM 340D)
-340C TR50-02A . . SEMICOND, XSTR (V08748)
(OPTIONAL)
-340D TR50-03AM . . SEMICOND, XSTR (V08748) 2
MATCHED PAIR
(SUPSDS ITEMS 340 AND 340A)
(REPLS ITEM 340B)
ATTACHING PARTS
345 MS35431-5 . . LUG 1
346 SSP73205-177PH . . WASHER, BELLEVILLE (V02368) 2
(WA25-01, V08748)
(CORRECT PN IS SSP-73205-177PH)
-346A WA25-01 . . WASHER, BELLEVILLE (V08748)
(OPTIONAL)
350 LT54-02 . . WASHER, INSULATING (V08748) 2
(SELECTED PART FOR ITEM 340)
(USED ON 0.050/0.073 THK FLNG)
-350A LT54-03 . . WASHER, INSULATING (V08748) 2

-350B LT54-04 . . WASHER, INSULATING (V08748) 2
-350C LT54-05 . . WASHER, INSULATING (V08748) 2
357 AN960C4 . . WASHER, FLAT
(CORRECT PN IS AN960-C4)
-357A NAS620C5 . . WASHER, FLAT (OPTIONAL)
(POST SB4-254-24-12)
-357B NAS620C5L . . WASHER, FLAT (SUPSDS ITEM 357) 2
(PART NUMBER CORRECTION)
365 MS51957-17 . . SCREW 2
***

Page 10049
24-31-04 May 25/12
4-254
UNITS
1–
370 TF50-366-01 . . INDUCTOR, SNUBBER, L1 (V08748)
(REPLD BY ITEM 370A)
-370A TF50-720-01 . . INDUCTOR, SNUBBER, L1 (V08748) 1
(REPLS ITEM 370)
ATTACHING PARTS
385 MS51957-17 . . SCREW 2
***
-387 MS25036-107 . . LUG 4
390 4-254411-01 DELETED
-390A 4-254311-01 DELETED
-390B 4-254511-01 . . CIRCUIT CARD ASSY, A2A1 (V08748) 1
(USED ON ITEM 310A)
-390C 4-254411-02 . . CIRCUIT CARD ASSY, A2A1 (V08748)
(OPTIONAL)
(USED ON ITEM 310A)
ATTACHING PARTS
395 MS51957-20 . . SCREW 4

***
405 4-254322-01 . HEAT SINK ASSY, LEFT, A4 (V08748) 1
406 CC34-01 . . CLAMP (V08748) (OPTIONAL)
-406A CC02-06N . . CLAMP (V08748) (OPTIONAL)
-406B CC02-06B . . CLAMP (V08748) 2
-406C 8958 . . CLAMP (V83330) (CC34-01, V08748)
(OPTIONAL)
-406D NAS1397P5N . . CLAMP (CC02-06N, V08748)
(OPTIONAL)
-406E NAS1397P5B . . CLAMP (CC02-06B, V08748)
(OPTIONAL)
-406F 770-1604 . . CLAMP (V18310) (CC02-06B, V08748)
(OPTIONAL)
407 MS51957-29 . . SCREW 1
408 MS15795-805 . . WASHER 1
410 4-254323-01 . . HEAT SINK, LEFT (V08748) 1
-410A 4-254423-01 . . HEAT SINK, LEFT (V08748)
(OPTIONAL)

Page 10050
24-31-04 May 25/12
4-254
UNITS
1–
411 A52E103KSW . . DELETED
-411A A54E103KSW . . CAP, 400VDC, 0.01 F, 10% (V12517)
(OPTIONAL) (CA88-01A, V08748)
-411B A52E103KSW . . CAP, 400VDC, 0.01 F, 10% (V12517) 2
(CA161-01, V08748)
-411C CA161-01 . . CAP, 400VDC, 0.01 F, 10% (V08748)
(OPTIONAL)
412 TE47-01 . . TERMINAL (V08748) 1
(TE47-01 IS REFERENCE/CODE
NUMBER FOR 572-4810-01-05-16,
V71279)
-412A 1127-41-05-16 . . TERMINAL (V18310)
(TE47-01, V08748) (OPTIONAL)
415 RER75F6R04R . . RESISTOR, 30W, 6.04  , 1% 2
ATTACHING PARTS
420 MS51957-14 . . SCREW 2
425 MS15795-803 . . WASHER, FLAT 2
***
430 TF50-321-01 . . INDUCTOR, OUTPUT, L1 (V08748) 1

ATTACHING PARTS
435 MS15795-805 . . WASHER, FLAT 3
440 MS51957-27 . . SCREW 3
***
445 AN101008 . . BOLT (REPLD BY ITEM 445A)
-445A NAS1801-3-8 . . SCREW (REPLS ITEM 445) 1
450 MS15795-808 . . WASHER, FLAT 2
455 MS35338-138 . . WASHER, LOCK 1
460 MS35650-304 . . NUT 1
465 4-254242-01 . . INSULATOR (V08748) 1
470 4-254324-01 . . DIODE ASSY, OUTPUT, A4A1 (V08748) 1
ATTACHING PARTS
475 MS51957-28 . . SCREW 2
480 LT30-02 . . WASHER, SHOULDER (V08748) 2
***

Page 10051
24-31-04 May 25/12
4-254
UNITS
1–
490 4-254325-01 . . . BLOCK, RECTIFIER MTG (V08748) 1
495 UTG5140 . . . RECTIFIER, CR1, CR2 (V12969)
(CR35-04A, V08748)
(PRE SB4-254-24-13)
-495A UTG8187 . . . RECTIFIER, CR1, CR2 (V12969)
(OPTIONAL)
(CR35-05A, V08748)
(POST SB4-254-24-13)
-495B CR35-05A . . . RECTIFIER, CR1, CR2 (V08748) 2
(SUPSDS ITEM 495)
(POST SB4-254-24-13)
-495C B1919 . . . RECTIFIER, CR1, CR2 (V06288)
(OPTIONAL)
(CR35-05A, V08748)
-495D SER1089H . . . RECTIFIER, CR1, CR2 (V30043)
(OPTIONAL)
(CR35-05A, V08748)
497 TE47-01 . . . TERMINAL INSULATED (V08748) 1
(TE47-01 IS REFERENCE/CODE
NUMBER FOR 572-4810-01-05-16)

-497A 1127-41-05-16 . . . TERMINAL (V18310)
(TE47-01, V08748) (OPTIONAL)
498 MS35431-1 . . . LUG 1
ATTACHING PARTS
499 MS15795-804 DELETED
499A MS15795-803 . . . WASHER, FLAT 1
500 MS51957-14 . . . SCREW 1
501 M83421-01-0192M . . . CAP, 400 VDC, 0.22 F, 10% 1
(CORRECT PN IS M83421/01-0192M)
***
505 4-254226-01 . . . SNUBBER OUTPUT ASSY (V08748) 1
ATTACHING PARTS
506 MS15795-803 . . . WASHER, FLAT 2
507 MS51957-17 . . . SCREW 2
***
525 M39014-02-1289 . . . . CAP, 200 VDC, 0.0033 F, 10% 2
530 RCR42G100JS . . . . RESISTOR, 10 , 2 W, 5% 2

Page 10052
24-31-04 May 25/12
4-254
UNITS
1–
535 TE22-02 . . . . LUG (V08748) 1
-535A 135 . . . . LUG (V79963) (OPTIONAL)
(TE22-02, V08748)
-537 MS25036-107 DELETED
ATTACHING PARTS
-538 MS51957-31 . . . . SCREW 1
-539 NAS620C6L . . . . WASHER, FLAT 1
-540 MS15795-803 DELETED
-541 MS35338-137 . . . . WASHER, LOCK 1
-542 MS35649-264 . . . . NUT 1
***
544 TF50-312-01 . . TRANSFORMER, OUTPUT, T1 1
(V08748)
ATTACHING PARTS
545 MS15795-807 . . WASHER, FLAT 6
550 MS51957-43 . . SCREW 6
***
584 MS25036-107 . . LUG 2

ATTACHING PARTS
585 MS51957-31 . . SCREW 1
600 MS35338-136 . . WSHER, LOCK 1
605 MS35649-264 . . NUT 1
***
606 AN101006 . . BOLT A, B 1
-606A NAS1801-3-6 . . SCREW C, D 1
(REPLS ITEM 606B)
-606B AN101006 . . BOLT C, D
607 MS15975-808 DELETED
-607A MS15795-808 . . WASHER, FLAT 2
608 AN101008 . . BOLT A, B
-608A NAS1801-3-8 . . SCREW C, D 1
(REPLS ITEM 608B)
-608B AN101008 . . BOLT C, D
609 MS35338-138 . . WASHER, LOCK 1
610 MS35650-304 . . NUT 1

Page 10053
24-31-04 May 25/12
4-254
IPL Figure 2
Input Assembly A1
24-31-04
Page 10054
May 25/12
4-254
UNITS
2–
-1 4-254301-01 INPUT ASSEMBLY, A1 (V08748) A RF
(SEE FIGURE 1 FOR NHA)
-1A 4-254301-02 INPUT ASSEMBLY, A1 (V08748) B RF
(SEE FIGURE 1 FOR NHA)
5 4-254302-01 . CHASSIS (V08748) 1
10 4-254207-01 . CAPACITOR SHIELD (V08748) 1
ATTACHING PARTS
15 MS51957-14 . SCREW, 4
***
25 TF50-315-01 . TRANSFORMER, T1 (V08748) 1
-25A TF50-197-01 . TRANSFORMER, T1 (V08748)
(OPTIONAL)
ATTACHING PARTS
26 MS24693C25 . SCREW 2
***
30 TF50-313-01 . INDUCTOR, L1 (V08748) 1
ATTACHING PARTS
32 MS24693C25 . SCREW 3
***
35 TF50-361-01 . INDUCTOR, L2, L4 (V08748) 1
(DUAL UNIT)
ATTACHING PARTS
36 MS24693C2 . SCREW 3
***
40 TF50-317-01 . INDUCTOR, L3 (V08748) (OPTIONAL)
-40A TF50-317-02 . INDUCTOR, L3 (V08748) 1
ATTACHING PARTS
42 MS24693C2 . SCREW 2
***

Page 10055
24-31-04 May 25/12
4-254
UNITS
2–
45 DA01-10A . SEMICOND, DIODE (V08748)
(REPLD BY ITEM 45A)
-45A JXM19500-483-03 . SEMICOND, DIODE 1
(REPLS ITEM 45)
(CORRECT PN IS JXM19500/483-03)
-45B DA01-18A . SEMICOND, DIODE (V08748)
(OPTIONAL)
ATTACHING PARTS
46 M24693C27 DELETED
-46A MS24693C27 . SCREW 2
48 MS21043-06 . NUT 2
***
115 4-254303-01 . CAPACITOR ASSY, A1A1 (V08748) 1
128 4-254304-01 . . BRKT, CAPACITOR MTG (V08748) 1
130 M83421-01-9300M . . CAP, 200 VDC, 2.7 F, 10% (OPTIONAL)
(CORRECT PN IS M83421/01-9300 M)
-130A M83421-01-4300S . . CAP, 200 VDC, 2.7 F, 10% (OPTIONAL)
(CORRECT PN IS M83421/01-4300S)
-130B M83421-01-4300M . . CAP, 200 VDC, 2.7 F, 10% (OPTIONAL)
-130C M83421-01-4299S . . CAP, 200VDC, 2.7 F, 10% (OPTIONAL)
-130D CA288-01 . . CAP, 200 VDC, 2.7 F, 10% (V08748) 3
135 4-254205-01 . CIRCUIT CD ASSY, A1A2 (V08748) A 1
-135A 4-254205-02 . CIRCUIT CD ASSY, A1A2 (V08748) B 1
-135B 4-254205-01 . CIRCUIT CD ASSY, A1A2 (V08748) B
(OPTIONAL)
ATTACHING PARTS
136 MS51975-15 DELETED
-136A MS51957-15 . SCREW 12
***
150 10-753-3-05 . . TERMINAL (V18310) 5
(TM15-01, V08748)
-150A TM15-01 . . TERMINAL (V08748) (OPTIONAL)
155 RCR20G104JS . . RESISTOR, 0.5 W, 100 K , 5% A
-155A RLR20C1003FS . . RESISTOR, 0.5 W, 100 K , 1% A 2
(REPLS ITEM 155)
-155B RLR20C1003GS . . RESISTOR, 0.5 W, 100 K , 2% A
(OPTIONAL)

Page 10056
24-31-04 May 25/12
4-254
UNITS
2–
-155C RLR20C1003GS . . RESISTOR, 0.5 W, 100 K , 2% B 2
-155D RCR20G104JS . . RESISTOR, 0.5 W, 100 K , 5% B
(OPTIONAL)
160 RCR42G221JS . . RESISTOR, 2 W, 220  , 5% (OPTIONAL)
-160A RWR80N2210FR . . RESISTOR, 2 W, 221  , 1% 1
165 M83421-01-9300M . . CAP, 200 VDC, 2.7 F, 10% (OPTIONAL)
-165A M83421-01-4300S . . CAP, 200 VDC, 2.7 F, 10% (OPTIONAL)
-165B M83421-01-4300M . . CAP, 200 VDC, 2.7 F, 10% (OPTIONAL)
-165C M83421-01-4299S . . CAP, 200 VDC, 2.7 F, 10% (OPTIONAL)
-165D CA288-01 . . CAP, 200 VDC, 2.7 F, 10% (V08748) 6
170 673D312A . . CAP, 250 VDC, 180 F, +100/-10% A 2
(V56289) (CA86-01A, V08748)
-170A CA86-01A . . CAP, 250VDC, 180 F, +100/-10%
(V08748) (OPTIONAL)
-170B CA280-181A . . CAP, 250 VDC, 180 F, +100/-10% B 2
(V08748)
-170C URZA457 . . CAP, 250 VDC, 180 F, +100/-10% B

(V7M138) (CA280-181A, V08748)
(OPTIONAL)
173 MS25036-102 . LUG 2
173A NAS620C6L . WASHER, FLAT 2
173B MS35338-136 . WASHER, LOCK, CRES 2
173C MS51957-26 . SCREW 2
175 CA92-01A . CAP, 500 VDC, 0.01 F, 10% (V08748) A 3
-175A CA92-01 . CAP, 500 VDC, 0.01 F, 10% (V08748) A
(OPTIONAL)
-175B CA92-11A . CAP, 500 VDC, 0.01 F, 10% (V08748) A
(OPTIONAL)
-175C 151B103K501LEXH . CAP, 500 VDC, 0.01 F, 10% (V65238) A
(CA92-01A, V08748) (OPTIONAL)
-175D CA92-11A . CAP, FXD, CERAMIC (V08748) B 3
-175E 102H46W103KQ3H . CAP, FXD, CERAMIC (V29454) B
-175F CA92-01A . CAP, 500 VDC, 0.01 F, 10% (V08748) B
(OPTIONAL)
180 JANTX1N5614 . SEMICOND, DIODE 6
-185 MS21266-2N . GROMMET, PLSTC, EDGING, AR
12.62/12.75 LG

Page 10057
24-31-04 May 25/12
4-254
BLANK
THIS PAGE
INTENTIONALLY
24-31-04
Page 10058
May 25/12
4-254

Circuit Card Assembly A3A1 (Configuration 4-254253-01/-02/-03/-04)
Page 10059
24-31-04 May 25/12
4-254

Page 10060
24-31-04 May 25/12
4-254

Circuit Card Assembly A3A1 (Configuration 4-254253-02/4-254453-02)
Page 10061
24-31-04 May 25/12
4-254

Circuit Card Assembly A3A1 (Assembly Details)
Page 10062
24-31-04 May 25/12
4-254

Page 10063
24-31-04 May 25/12
4-254

Page 10064
24-31-04 May 25/12
4-254

Circuit Card Assembly A3A1 (Configuration 4-254453-01/-03)
Page 10065
24-31-04 May 25/12
4-254

Page 10066
24-31-04 May 25/12
4-254

Page 10067
24-31-04 May 25/12
4-254

Page 10068
24-31-04 May 25/12
4-254

Page 10069
24-31-04 May 25/12
4-254

Page 10070
24-31-04 May 25/12
4-254
UNITS
3–
-1 4-254253-01 CIRCUIT CARD ASSY, A3A1 (V08748) A RF
(ESDS) (SEE FIGURE 1 FOR NHA)
-1A 4-254253-02 CIRCUIT CARD ASSY, A3A1 (V08748) B RF
-1B 4-254353-01 CIRCUIT CARD ASSY, A3A1 (V08748) C RF
-1C 4-254353-02 CIRCUIT CARD ASSY, A3A1 (V08748) D RF
-1D 4-254553-01 CIRCUIT CARD ASSY, A3A1 (V08748) E RF
-1E 4-254453-01 CIRCUIT CARD ASSY, A3A1 (V08748) F RF
-1F 4-254453-02 CIRCUIT CARD ASSY, A3A1 (V08748) G RF
-1G 4-254253-03 CIRCUIT CARD ASSY, A3A1 (V08748) H RF
-1H 4-254253-04 CIRCUIT CARD ASSY, A3A1 (V08748) I RF
-1J 4-254353-03 CIRCUIT CARD ASSY, A3A1 (V08748) J RF
-1K 4-254353-04 CIRCUIT CARD ASSY, A3A1 (V08748) K RF

-1L 4-254553-02 CIRCUIT CARD ASSY, A3A1 (V08748) L RF
-1M 4-254453-03 CIRCUIT CARD ASSY, A3A1 (V08748) M RF
-1N 4-254453-04 CIRCUIT CARD ASSY, A3A1 (V08748) N RF
10 526700-02 . INSULATOR (V07047) 1
(LT20-2, V08748)
-10A LT20-2 . INSULATOR (V08748) (OPTIONAL)
15 M38527-3-02D . PAD A-D 9
(CORRECT PN IS M38527/3-02D) F-J, K
-15A M38527-03-002D . PAD E, L 9
(CORRECT PN IS M38527/03-002D)
-15B M38527-03-002D . PAD M, N 9
(REPLS ITEM 15C)
-15C M38527-3-02D . PAD M, N
(REPLD BY ITEM 15B)

Page 10071
24-31-04 May 25/12
4-254
UNITS
3–
20 CDIP578060-1C DELETED
-20A CDIP578040-1C . INSULATOR (V19080) (SUSPS ITEM 20) A-D, F-K, 8
(TP09-03, V08748) M-N
-20B TP09-03 . INSULATOR (V08748) (OPTIONAL) A-D, F-K,
M-N
25 WTB20PR7J548 . CONNECTOR (V10400) 1
(CN73-02, V08748)
-25A CN73-02 . CONNECTOR (V08748) (OPTIONAL)
ATTACHING PARTS
26 MS51957-18 . SCREW A, B, G-I, 1
N
-26A MS51957-15 . SCREW C-F, J-M 1
27 MS35649-244 . NUT A, B, G-I, 1
N
28 STD111-8 . LUG, (V08748) (SUPSDS ITEM 28A) ABHI 1
-28A 11A120 . LUG, (V08748) (SUPSD BY ITEM 28) ABHI
31 MS51957-15 . SCREW 1
35 MS35338-135 . WASHER, LOCK A, B, G-I, 3
N
-35A MS35338-135 . WASHER, LOCK C-F, J-M 2

40 NAS620C4L . WASHER, FLAT A, B, G-I, 4
N
-40A NAS620C4L . WASHER, FLAT C-F, J-M 2
41 NAS620C4L DELETED
42 BD11-13 . INSULATOR (V08748) C-D, F, 1
J, K, M
***
45 JANTX2N3741 . SEMICOND, XSTR 1
ATTACHING PARTS
52 MS51957-16 . SCREW 2
55 NAS620C4L . WASHER A, B, H, I 2
-55A AN960C4 . WASHER, FLAT C-G, J-N 2

Page 10072
24-31-04 May 25/12
4-254
UNITS
3–
57 AN960C4 DELETED
58 SP73205-177 DELETED
-58A SSP73205-177PH . WASHER, BELLEVILLE (V02368) 2
(WA25-01, V08748)
(POST SB4-254-24-09)
-58B WA25-01 . WASHER, BELLEVILLE (V08748)
(OPTIONAL)
60 LT54-01 . INSULATOR (V60204) 2
(POST SB4-254-24-09)
70 MS35431-3 . LUG A-C, H-J 1
-70A MS35431-5 . LUG D-G, K-N 1
75 69-11B523-1678 . INSULATOR (V18565) (LT74-02, V08748) 1
(POST SB4-254-24-09)
(CORRECT PN IS 69-11-B523-1678)
***
80 SG140-12K883B . MICROCIRCUIT (V34333) 1
(AR11-18, V08748)
(CORRECT PN IS SG140-12K/883B)
-80A AR11-18 . MICROCIRCUIT (V08748) (OPTIONAL)
ATTACHING PARTS
85 LT54-02 . WASHER (V60204) 2
95 MS35431-5 . LUG 1
100 MS51957-16 . SCREW 2
101 SSP73205-177PH . WASHER, BELLEVILLE (V02368) 2
(WA25-01, V08748)
-101A WA25-01 . WASHER, BELLEVILLE (V08748)
(OPTIONAL)
105 69-11B522-1678 . INSULATOR (V18565) (LT74-01, V08748) 1
(POST SB4-254-24-09)
(CORRECT PN IS 69-11-B522-1678)
110 NAS620C4L . WASHER, FLAT A, B, H, I 2
-110A AN960C4 . WASHER, FLAT C-G, J-N 2
***

Page 10073
24-31-04 May 25/12
4-254
UNITS
3–
115 4-254241-01 . HEAT SINK, XSTR MTG (V08748) 1
ATTACHING PARTS
116 MS51957-15 . SCREW 2
***
120 LM124J883C . MICROCIRCUIT (V27014) 2
(AR19-02, V08748)
(CORRECT PN IS LM124J/883C)
125 M556DC883B . MICROCIRCUIT (V07933)
(AR37-08, V08748)
-125B SE556JB . MICROCIRCUIT (V01295) 1
(AR37-08, V08748)
(SUPSDS ITEM 125)
130 CD4024BMJ883 . MICROCIRCUIT (V27014) 1
(CM05-024BA, V08748)
(CORRECT PN IS CD4024BMJ/883)
-130A CM05-024BA . MICROCIRCUIT (V08748) (OPTIONAL)

(CM05-023BA, V08748)
(CM05-0193BA, V08748)
145 CD4072BMJ883 DELETED
-145A CD4072BMJL883 . MICROCIRCUIT (V27014) 1
(CM05-072BA, V08748)
(CORRECT PN IS CD4072BMJL/883)
-145B CM05-072BA . MICROCIRCUIT (V08748) (OPTIONAL)
150 JANTX2N2222A . SEMICOND, XSTR 6
155 JANTX2N2907A . SEMICOND, XSTR 3
-155A JANTXV2N2907A . SEMICOND, XSTR (OPTIONAL) L
165 JANTX1N825 . SEMICOND, DIODE (OPTIONAL)
-165A JANTX1N825-1 . SEMICOND, DIODE 2
170 JANTX1N758A1 . SEMICOND, DIODE 2
(CORRECT PN IS JANTX1N758A-1)
-170A JANTX1N758A . SEMICOND, DIODE (OPTIONAL) A-K, M-N

Page 10074
24-31-04 May 25/12
4-254
UNITS
3–
175 JANTX1N756A1 . SEMICOND, DIODE A-I, K, 2
(CORRECT PN IS JANTX1N756A-1) L, N
-175A JANTX1N756A . SEMICOND, DIODE (OPTIONAL) A-I, N
-175B JANTX1N756A . SEMICOND, DIODE J, M 2
-175C JANTX1N756A1 . SEMICOND, DIODE (OPTIONAL) J, M
180 JANTX1N4148-1 . SEMICOND, DIODE 25
181 JANTX1N4148-1 . SEMICOND, DIODE B-G, I-N 1
(POST SB4-254-24-09)
185 M83421-01-6171M . CAP, 30 VDC, 0.1 F, 1% 1
190 M39018-01-0740 . CAP, 75 VDC, 22 F, +75/-10% 1
194 M39014-02-1320 . CAP, 50 VDC, 0.47 F, 10% 1
-194A M39014-02-1360 . CAP, 50 VDC, 0.47 F, 10%
(OPTIONAL)
195 M39014-02-1415 . CAP, 50 VDC, 1 F, 10% 4
196 M39014-02-1415 . CAP, 50 VDC, 1 F, 10% E-G 1

(POST SB4-254-24-09) L-N
-196A M39014-02-1358 . CAP, 50 VDC, 0.33 F, 10% A-D 1
(CORRECT PN IS M39014/02-1358) H-K
200 M39014-02-1358 . CAP, 50 VDC, 0.33 F, 10% 1
205 M39014-02-1310 . CAP, 100 VDC, 0.1F, 10% 1
210 M39014-01-1553 . CAP, 50 VDC, 0.1 F, 10% 14
215 M39014-01-1535 . CAP, 100 VDC, 0.01 F, 10% 4
216 M39014-01-1535 . CAP, 100 VDC, 0.01 F, 10% B-G, I-N 1
(POST SB4-254-24-09)
217 CA92-01A . CAP, 500 VDC, 0.01 F, 10% (V08748) 1
-217A CA92-01 . CAP, 500 VDC, 0.01 F, 10% (V08748)
(OPTIONAL)
-217B 151B103K501LEXH . CAP, 500 VDC, 0.01 F, 10% (V65238)
218 RCCS280075-1V . INSULATOR, CAPACITOR (V19080) C-F, J-M 1
(LT73-01, V08748) (UNDER ITEM 217)
(CORRECT PN IS RC-CS280075-1V)
-218A LT73-01 . INSULATOR, CAPACITOR (V08748) C-F, J-M
(OPTIONAL)

Page 10075
24-31-04 May 25/12
4-254
UNITS
3–
220 RWR89S1R00FR . RESISTOR, 3 W, 1 , 1% 1
225 RWR81S3830FR . RESISTOR, 1 W, 383 , 1% 1
230 RNC55H2671FS . RESISTOR, 0.1 W, 2.67 K, 1% A, C-G, 3
H, J-N
-230A RNC55H2671BS . RESISTOR, 0.1 W, 2.67 K, 0.1% C-G, J-N
(OPTIONAL)
-230B RNC55H2671FS DELETED
-230C RNC55H2671BS . RESISTOR, 0.1 W, 2.67 K, 0.1% B, I 3
-230D RNC55H2671FS . RESISTOR, 0.1 W, 2.67 K, 1% B, I
(OPTIONAL)
235 RNC55H2672FS . RESISTOR, 0.1 W, 26.7 K, 1% A, H 1
-235A RNC55H2642BS . RESISTOR, 0.1 W, 26.4 K, 0.1% B-G, I-N 1
(POST SB4-254-24-09)
-235B RNC55H2672FS . RESISTOR, 0.1 W, 26.7 K, 1% B, I
(OPTIONAL)
-235C RNC55H2642FS . RESISTOR, 0.1 W, 26.4 K, 1% C-G, J-N
(OPTIONAL)
240 RNC55H2152FS . RESISTOR, 0.1 W, 21.5 K, 1% 1
250 RNC55H2872FS . RESISTOR, 0.1 W, 28.7 K, 1% A, C-G, 2
H, J-N
-250A RNC55H2872BS . RESISTOR, 0.1 W, 28.7 K, 0.1% B, I 2
(POST SB4-254-24-09)
-250C RNC55H2872FS . RESISTOR, 0.1 W, 28.7 K, 1% B, I
(OPTIONAL)
-250D RNC55H2872BS . RESISTOR, 0.1 W, 28.7 K, 0.1% C-G, J-N
(OPTIONAL)
260 RNC55H4641FS . RESISTOR, 0.1 W, 4.64 K, 1% A, C, H, J 3
-260A RNC55H4641BS . RESISTOR, 0.1 W, 4.64 K, 0.1% B, D-G, 3
(POST SB4-254-24-09) I, K-N
-260C RNC55H4641FS . RESISTOR, 0.1 W, 4.64 K, 1% B, D-G,
(OPTIONAL) I, K-N
-260D RNC55H4641BS . RESISTOR, 0.1 W, 4.64 K, 0.1% C, J
(OPTIONAL)
270 RNC55H5622FS . RESISTOR, 0.1 W, 56.2 K, 1% A-D, H-K 1
-270A RNC55H4992FS . RESISTOR, 0.1 W, 49.9 K, 1% E-G, L-N 1
(POST SB4-254-24-09)

Page 10076
24-31-04 May 25/12
4-254
UNITS
3–
-275A RNC55H6811BS . RESISTOR, 0.1 W, 6.81 K, 0.1% B, I 1
-275B RNC55H6811FS . RESISTOR, 0.1 W, 6.81 K, 1% B, I
(OPTIONAL)
-275C RNC55H7871BS . RESISTOR, 0.1 W, 7.87 K, 0.1% D-G, K-N 1
(POST SB4-254-24-09)
-275D RNC55H7871FS . RESISTOR, 0.1 W, 7.87 K, 1% D-G, K-N
(OPTIONAL)
-275E RNC55H6811FS . RESISTOR, 0.1 W, 6.81 K, 1% C, J 1
-275F RNC55H6811BS . RESISTOR, 0.1 W, 6.81 K, 0.1% C, J
(OPTIONAL)
-280A RNC55H5231BS . RESISTOR, 0.1 W, 5.23 K, 0.1% B, C, I, J 1
-280B RNC55H5231FS . RESISTOR, 0.1 W, 5.23 K, 1% B, C, I, J
(OPTIONAL)
-280C RNC55H4221BS . RESISTOR, 0.1 W, 4.22 K, 0.1% D-G, K-N 1
(POST SB4-254-24-09)
-280D RNC55H4221FS . RESISTOR, 0.1 W, 4.22 K, 1% D-G, K-N
(OPTIONAL)

-287A RNC55H2001FS . RESISTOR, 0.1 W, 2 K, 1% B-G, I-N 1
(POST SB4-254-24-09)
290 RNC55H1211FS . RESISTER, 0.1 W, 1.21 K, 1% 2
(SELECTED VALUE RANGE: 6.19 K
TO 7.68 K)
-295A RNC55H7151BS . RESISTER, 0.1 W, 7.15 K, 0.1% B, I 1
TO 7.68 K)
-295C RNC55H6191BS . RESISTOR, 0.1 W, 6.19 K, 0.1% C-G, J-N 1
TO 8.25 K)
-295D RNC55H6191FS . RESISTOR, 0.1 W, 6.19 K, 1% C-G, J-N
TO 8.25 K) (OPTIONAL)
-295E RNC55H7151FS . RESISTOR, 0.1 W, 7.15 K, 1% B, I
TO 7.68 K) (OPTIONAL)

Page 10077
24-31-04 May 25/12
4-254
UNITS
3–
TO 6.65)
-296A RNC55H6043BS . RESISTOR, 0.1 W, 604 K, 0.1% B-G, I-N 1
TO 1.21 M)
-296B RNC55H6193FS . RESISTOR, 0.1 W, 604 K, 0.1% B-G, I-N
(OPTIONAL)
-296C RNC55H6043FS . RESISTOR, 0.1 W, 604 K, 0.1% B-G, I-N
TO 1.21 M) (OPTIONAL)
300 RLR07C2702GR . RESISTOR, 0.25 W, 27 K, 2% A, H 1
-300A RNC55H6652BS . RESISTOR, 0.1 W, 66.5 K, 0.1% B-G, I-K, 1
(POST SB4-254-24-09) M, N
-300B RNC55H6652FS . RESISTOR, 0.1 W, 66.5 K, 1% B-G, I-K,
(OPTIONAL) M, N
-300C RNC55H6652FS . RESISTOR, 0.1 W, 66.5 K, 1% L 1
-300D RNC55H6652BS . RESISTOR, 0.1 W, 66.5 K, 0.1% L
(OPTIONAL)
302 RLR07C5101GS . RESISTOR, 0.25 W, 5.1 K, 2% E, L 1
305 RCR20G102JS . RESISTOR, 0.5 W, 1 K, 5% A-K 1

-305A RLR20C1001FS . RESISTOR, 0.5 W, 1 K, 1% L-N 1
(REPLS ITEM 305B)
-305B RCR20G102JS . RESISTOR, 0.5 W, 1 K, 5% L-N
310 RCR07G222JS . RESISTOR, 0.25 W, 2.2 K, 5% A-D, F-K 2
-310A RLR07C2201GS . RESISTOR, 0.25 W, 2.2 K, 2% E, L-N 2
(REPLS ITEM 310B)
-310B RCR07G222JS . RESISTOR, 0.25 W, 2.2 K, 5% E, L-N
315 RCR07G153JS . RESISTOR, 0.25 W, 15 K, 5% A-D, F-K 2
-315A RLR07C1502FS . RESISTOR, 0.25 W, 15 K, 1% E, L-N 2
(REPLS ITEM 315B)
-315B RCR07G153JS . RESISTOR, 0.25 W, 15 K, 5% E, L-N
316 RCR07G153JS . RESISTOR, 0.25 W, 15 K, 5% A-D, H-K 1
-316A RLR07C4301GS . RESISTOR, 0.25 W, 4.3 K, 2% E-G, L-N 1
317 RCR07G153JS . RESISTOR, 0.25 W, 15 K, 5% E, L 1
-317A RLR07C1502FS . RESISTOR, 0.25 W, 15 K, 1% E, L
(REPLS ITEM 317)

Page 10078
24-31-04 May 25/12
4-254
UNITS
3–
(REPLS ITEM 320B)
325 RCR07G223JS . RESISTOR, 0.25 W, 22 K, 5% A, H 1
-326A RLR07C2202GS . RESISTOR, 0.25 W, 22 K, 2% E, L-N 1
(REPLS ITEM 326B)
-327A RNC55H1002BS . RESISTOR, 0.1 W, 10 K, 0.1% C-G, I-N 1
(POST SB4-254-24-09)
-327B RNC55H1002FS . RESISTOR, 0.1 W, 10 K, 1% C-G, I-N
(OPTIONAL)
-327C RNC55H1002FS . RESISTOR, 0.1 W, 10 K, 1% B 1
-327D RNC55H1002BS . RESISTOR, 0.1 W, 10 K, 0.1% B
(OPTIONAL)
-330A RLR07C1202GS . RESISTOR, 0.25 W, 12 K, 2% E, L

(REPLD BY ITEM 330B)
-330B RCR07G1212FS . RESISTOR, 0.25 W, 12 K, 1% E, L 1
(REPLS ITEMS 330A AND 330C)
-330C RCR07G123JS . RESISTOR, 0.25 W, 12 K, 5% E, L
-330D RLR07C1202GS . RESISTOR, 0.25 W, 12 K, 2% M, N
(REPLD BY ITEM 330E)
-330E RCR07G123JS . RESISTOR, 0.25 W, 12 K, 5% M, N 1
(REPLS ITEM 330D)
-335A RLR07C2203GS . RESISTOR, 0.25 W, 220 K, 2% E-G, L 1
(POST SB4-254-24-09)
-335B RLR07C2203GS . RESISTOR, 0.25 W, 220 K, 2% M, N 1
(REPLS ITEM 335C)
-335C RCR07G224JS . RESISTOR, 0.25 W, 220 K, 5% M, N 1
(REPLS ITEM 340B)

Page 10079
24-31-04 May 25/12
4-254
UNITS
3–
345 RCR07G100JS . RESISTOR, 0.25 W, 10 , 5% A-D, F-K 1
-345A RLR07C10R0FS . RESISTOR, 0.25 W, 10 , 1% E, L-N 1
(REPLS ITEM 345B)
-345B RCR07G100JS . RESISTOR, 0.25 W, 10 , 5% E, L-N
350 RCR07G101JS . RESISTOR, 0.25 W, 100 , 5% A-D, F-K 1
-350A RLR07C1000FS . RESISTOR, 0.25 W, 100 , 1% M-N 1
(REPLS ITEM 350B)
-350B RCR07G101JS . RESISTOR, 0.25 W, 100 , 5% M-N
-350C RLR07C20R0FR . RESISTOR, 0.25 W, 20 , 1% E, L 1
(REPLS ITEMS 350E, 350F, AND 350G)
-350D RLR07C20R0FS . RESISTOR, 0.25 W, 20 , 1% E, L
(OPTIONAL)
-350E RCR07G101JS . RESISTOR, 0.25 W, 100 , 5% E, L
-350F RLR07C1000FS . RESISTOR, 0.25 W, 100 , 1% E, L
-350G RLR07C27R0GS . RESISTOR, 0.25 W, 27 , 1% E, L
355 RCR07G105JS . RESISTOR, 0.25 W, 1 M, 5% A-D, F-K 2

-355A RLR07C1004FS . RESISTOR, 0.25 W, 1 M, 1% E, L-N 2
(REPLS ITEM 355B)
-355B RCR07G105JS . RESISTOR, 0.25 W, 1 M, 5% E, L-N
-360A RCR07G104FS . RESISTOR, 0.25 W, 100 K, 1% L
-360B RLR07C1003FS . RESISTOR, 0.25 W, 100 K, 1% E, L-N 4
(REPLS ITEM 360C)
(SUPSDS ITEM 360A)
-360C RCR07G104JS . RESISTOR, 0.25 W, 100 K, 5% E, L-N
-361A RLR07G3302GS DELETED
-361B RCR07G104JS . RESISTOR, 0.25 W, 1 K, 5% M, N
-361C RLR07C1003FS . RESISTOR, 0.25 W, 100 K, 1% M, N 1
(REPLS ITEM 361B)

Page 10080
24-31-04 May 25/12
4-254
UNITS
3–
(REPLS ITEM 362C)
-362C RCR07G333JS . RESISTOR, 0.25 W, 33 K, 5% M, N
-365A RLR07C2701GS . RESISTOR, 0.25 W, 2.7 K, 2% E, L-N 1
(REPLS ITEM 365B)
-365B RCR07G272JS . RESISTOR, 0.25 W, 2.7 K, 5% E, L-N
-370A RLR07C2703GS . RESISTOR, 0.25 W, 270 K, 2% E, L-N 1
(REPLS ITEM 370B)
-375A RCR07G152JS DELETED
-375B RLR07C1501FS . RESISTOR, 0.25 W, 1.5 K, 1% E, L-N 2
(REPLS ITEM 375C)
-375C RCR07G152JS . RESISTOR, 0.25 W, 1.5 K, 5% E, L-N

376 RLR20C2401GS . RESISTOR, 0.5 W, 2.4 K, 2% H-N 1
(POST SB4-254-24-10)
377 RCR07G152JS . RESISTOR, 0.25 W, 1.5 K, 5% A-D, F-G 1
-377A RLR07C1501FS . RESISTOR, 0.25 W, 1.5 K, 1% E 1
(REPLS ITEM 377B)
-377B RCR07G152JS . RESISTOR, 0.25 W, 1.5 K, 5% E
(REPLS ITEM 380C)
-380C RCR07G333JS . RESISTOR, 0.25 W, 33 K, 5% M, N
381 RLR07C3302GS DELETED

Page 10081
24-31-04 May 25/12
4-254
UNITS
3–
385 RNC60H2674FS . RESISTOR, 0.125 W, 2.67 M, 1% A, H 1
(SELECTED VALUE, RANGE: 2.61 M
TO 2.74 M)
-385A RNC60H2674BS . RESISTOR, 0.125 W, 2.67 M, 0.1% B, I 1
TO 2.74 M)
-385C RNC60H2674BS . RESISTOR, 0.125 W, 2.67 M, 0.1% C-G, J-N 1
TO 3.01 M)
-385D RNC60H2674FS DELETED
-385E RNC60H2674FM . RESISTOR, 0.125 W, 2.67 M, 1% A, B, H, I
(OPTIONAL)
TO 2.74 M)
-385F RNC60H2674FS . RESISTOR, 0.125 W, 2.67 M, 1% B, I
(OPTIONAL)
TO 2.74 M)
-385G RNC60H2674FM . RESISTOR, 0.125 W, 2.67 M, 0.1% C-G, J-N
(OPTIONAL)
TO 3.01 M)
-385H RNC60H2674FS . RESISTOR, 0.125 W, 2.67 M, 0.1% C-G, J-N
(OPTIONAL)
TO 3.01 M)
-390A RLR07C2213FS . RESISTOR, 0.25 W, 221 K, 1% E, L 1
-390B RCR07G224JS . RESISTOR, 0.25 W, 220 K, 5% E, L
(OPTIONAL)
-390C RLR07C2203GS . RESISTOR, 0.25 W, 220 K, 2% M, N 1
-390D RCR07G224JS . RESISTOR, 0.25 W, 220 K, 5% M, N
(OPTIONAL)
(OPTIONAL)

Page 10082
24-31-04 May 25/12
4-254
UNITS
3–
-400A RNC55H2252BS DELETED
-400C RLR07C4702GS . RESISTOR, 0.25 W, 47 K, 2% L
-400D RLR07C4752FS . RESISTOR, 0.25 W, 47.5 K, 1% E, L 4
(REPLS ITEMS 400C AND 400E)
-400E RCR07G473JS . RESISTOR, 0.25 W, 47 K, 5% E, L
-400F RLR07C4702GS . RESISTOR, 0.25 W, 47 K, 2% M, N 4
(REPLS ITEM 400G)
-400G RCR07G473JS . RESISTOR, 0.25 W, 47 K, 5% M, N
(REPLD BY ITEM 400F)
-401A RNC55H2552FS . RESISTOR, 0.1 W, 25.5 K, 1% B-G, I-N
(OPTIONAL)
-401B RNC55H2552BS . RESISTOR, 0.1 W, 25.5 K, 0.1% B-G, I-N 1
402 RCR07G473JS DELETED
405 RCR07G106JS . RESISTOR, 0.25 W, 10 M, 5% A-D, F-K 2
-405A RLR07C1005FS . RESISTOR, 0.25 W, 10 M, 1% N 2
(REPLS ITEM 405J)

-405B RLR07C1005FS . RESISTOR, 0.25 W, 10 M, 1% E, L
(OPTIONAL)
-405C RLR07C1005FR . RESISTOR, 0.25 W, 10 M, 1% E, L 2
(REPLS ITEM 405E)
-405D RLR07C1005FP . RESISTOR, 0.25 W, 10 M, 1% E, L, M, N
(OPTIONAL)
-405E RCR07G106JS . RESISTOR, 0.25 W, 10 M, 5% E, L
-405F RLR07C1005FR . RESISTOR, 0.25 W, 10 M, 1% M 2
(REPLS ITEM 405G)
(SUPSDS ITEM 405H)
-405G RCR07G106JS . RESISTOR, 0.25 W, 10 M, 5% M
(REPLD BY ITEM 405F)
-405H RLR07C1005FS . RESISTOR, 0.25 W, 10 M, 1% M
(SUPSD BY ITEM 405F)
-405J RCR07G106JS . RESISTOR, 0.25 W, 10 M, 5% N

Page 10083
24-31-04 May 25/12
4-254
UNITS
3–
410 RCR07G155JS . RESISTOR, 0.25 W, 1.5 M, 5% A-D, F-K 1
-410A RLR07C1504FS . RESISTOR, 0.25 W, 1.5 M, 1% E, L-N 1
(REPLS ITEM 410B)
-410B RCR07G155JS . RESISTOR, 0.25 W, 1.5 M, 5% E, L-N 1
415 RCR07G681JS . RESISTOR, 0.25 W, 680 , 5% A-D, H-K 1
(POST SB4-254-24-09)
-415A RLR07C10R0GS . RESISTOR, 0.25 W, 10 , 2% E-G, L-N 1
-420A RLR07C3322FS . RESISTOR, 0.25 W, 33.2 K, 1% E, L 2
(REPLS ITEM 420B)
-420B RCR07G333JS . RESISTOR, 0.25 W, 33 K, 5% E, L
-420C RLR07C3302GS . RESISTOR, 0.25 W, 33 K, 2% M, N 2
(REPLS ITEM 420D)
-420D RCR07G333JS . RESISTOR, 0.25 W, 33 K, 5% M, N
425 2-36151-2 . LUG (V00779) (TE12-1, V08748) A, B, H, I 1
-425A MS25036-102 . LUG, CRP, INSLD, 22-18 WIRE SIZE A, B, H, I 1
(REPLS ITEM 425)

-425B TE12-1 . LUG (V08748) (OPTIONAL) A, B, H, I
430 M39014-01-1317 . CAP, 200VDC, 0.001 F, 10% B-D, I-K 1
(POST SB4-254-24-09)
435 RNC55H3013FS . RESISTOR, 0.1 W, 301 K, 1% 1
440 RLR07C4301GS . DELETED
470 09-8061-2-035 . PIN, SOLID (V18310) (PN11-18, V08748) E, L 7
-470A PN11-18 . PIN, SOLID (V08748) (OPTIONAL) E, L
475 PR32-62 . SPACER, SLEEVE, SOLID (V08748) E, L 9
480 10-805-2-05 . TERMINAL, POST (V18310) E, L 6
(TM14-02, V08748)
-480A TM14-02 . TERMINAL, POST (V08748) (OPTIONAL) E, L
485 10-301-2-05 . TERMINAL, TURRET (V18310) E, L 7
(TM13-02, V08748)
-485A TM13-02 . TERMINAL, TURRET (V08748) E, L
(OPTIONAL)

Page 10084
24-31-04 May 25/12
4-254
BLANK
THIS PAGE
INTENTIONALLY
24-31-04
Page 10085
May 25/12
4-254

Page 10086
24-31-04 May 25/12
4-254

Page 10087
24-31-04 May 25/12
4-254

Circuit Card Assembly A3A2 (configuration 4-254255-02)
Page 10088
24-31-04 May 25/12
4-254

Circuit Card Assembly A3A2 (Connector Assembly)
Page 10089
24-31-04 May 25/12
4-254

Page 10090
24-31-04 May 25/12
4-254

Page 10091
24-31-04 May 25/12
4-254

Page 10092
24-31-04 May 25/12
4-254

Page 10093
24-31-04 May 25/12
4-254

Page 10094
24-31-04 May 25/12
4-254

Circuit Card Assembly A3A2 (Configuration 4-254655-03)
Page 10095
24-31-04 May 25/12
4-254

Page 10096
24-31-04 May 25/12
4-254

Page 10097
24-31-04 May 25/12
4-254

Page 10098
24-31-04 May 25/12
4-254

Page 10099
24-31-04 May 25/12
4-254

Page 10100
24-31-04 May 25/12
4-254
UNITS
4–
-1D 4-254655-01 CIRCUIT CARD ASSY, A3A2 (V08748) E RF
-1E 4-254655-02 CIRCUIT CARD ASSY, A3A2 (V08748) F RF
-1F 4-254655-03 CIRCUIT CARD ASSY, A3A2 (V08748) G RF
-1G 4-254755-01 CIRCUIT CARD ASSY, A3A2 (V08748) H RF
10 M38527-3-02D . PAD, SEMICOND A-D 12
-10A M38527-03-002D . PAD, SEMICOND (REPLS ITEM 10B) E-G 12
-10B M38527-3-02D . PAD, SEMICOND (REPLD BY ITEM 10A) E-G

-10C M38527-03-002D . PAD, SEMICOND H 12
15 M38527-02-038D . PAD (TP13-01, V08748) 8
-15A 10099DAP DELETED
-15B TP13-01 . PAD (V08748) (OPTIONAL)
20 RCDIP578040-1C . INSULATOR, DIP (V19080) A-E 7
(TP09-03, V08748) (REPLS ITEM 20A)
-20A RCDIP578060-1C . INSULATOR, DIP (V19080) (OPTIONAL) A-E
(TP09-02, V08748)
(REPLD BY ITEM 20)
-20B RCDIP578040-1C . INSULATOR, DIP (V19080) F, G 7
(TP09-03, V08748)
-20C TP09-03 . INSULATOR, DIP (V08748) (OPTIONAL)
25 WTB20PR7J548 . CONNECTOR (V10400) 1
(CN73-02, V08748)
-25A CN73-02 . CONNECTOR (V08748) (OPTIONAL)
ATTACHING PARTS
26 MS51957-120 . SCREW A, B, G 1
-26A MS51957-15 . SCREW C-F, H 1
27 MS35649-244 . NUT A, B, G 1

Page 10101
24-31-04 May 25/12
4-254
UNITS
4–
28 11A . LUG (V79963) A, B, G 1
(STD111-8, V08748)
(SUPSDS ITEM 28A)
-28A 11A120 . LUG (V79963) (LU15-03, V08748) A, B, G
(SUPSD BY ITEM 28)
-28B STD111-8 . LUG (V08748) (OPTIONAL) A, B, G
30 MS51957-15 . SCREW 1
35 MS35338-135 . WASHER, LOCK 2
42 WA28-02 . WASHER, INSULATING (V08748) C, F 1
***
45 10459DAP . INSULATOR (V0ZK84) (LT20-1, V08748) 5
-45A LT20-1 . INSULATOR (OPTIONAL)
50 380635-3 DELETED
-50A 09-9002-1-03 . SOCKET (V18310) (OPTIONAL)
(KT36-02, V08748)
-50B REF02 . SOCKET (V3N087) (CORRECT PN IS A-G 7
0314-0-15-15-34-26-10-0)
(KT36-02, V08748)
(SUPSDS ITEMS 50 AND 50C)
-50C SC01-01 . SOCKET (V08748) A-G

(SUPSD BY ITEM 50B)
-50D REF03 . SOCKET (V3N087) (CORRECT PN IS H 7
0314-0-15-15-34-26-10-0)
(KT36-02, V08748)
(REPLS ITEM 50E)
-50E SC01-01 . SOCKET (V08748) H
(REPLD BY ITEM 50D)
-50F KT36-02 . SOCKET (V08748) (OPTIONAL)
55 LM119H883 . MICROCIRCUIT (V27014) 1
(AR21-02, V08748)
(CORRECT PN IS LM119H/883)
60 SG1524J883B . MICROCIRCUIT (V34333) A-D 1
(AR48-02, V08748)
-60A AR122-06 . MICROCIRCUIT (V08748) F-H 1
(POST SB4-254-24-09)
-60B 5962-8764501EX . MICROCIRCUIT (V67268) E 1
-60C AR48-02 . MICROCIRCUIT (V08748) (OPTIONAL) A-D
-60D AR122-06 . MICROCIRCUIT (V08748) (OPTIONAL) E
-60E 5962-8764501EX . MICROCIRCUIT (V67268) (OPTIONAL) H

Page 10102
24-31-04 May 25/12
4-254
UNITS
4–
65 DM54LS221J883C . MICROCIRCUIT (V27014) 2
(TL11-221B, V08748)
(CORRECT PN IS DM54LS221J/883C)
-65A TL11-221B . MICROCIRCUIT (V08748) (OPTIONAL)
-65B SN54LS221JSNJ . MICROCIRCUIT (V01295) (OPTIONAL)
(TL11-221B, V08748)
-65C SN54LS221JBCBJC . MICROCIRCUIT (V04713) (OPTIONAL)
(TL11-221B, V08748)
(TL11-00B, V08748)
(TL11-00B, V08748)
(TL11-00B, V08748)
(TL11-08B, V08748)

(TL11-08B, V08748)
(TL11-08B, V08748)
80 DS55325J883 . MICROCIRCUIT (V27014)
(SUPSD BY ITEM 80A)
(UF02-02, V08748)
-80A SG55325J883 . MICROCIRCUIT (V19645) 2
(SUPSDS ITEM 80) (UF02-02, V08748)
(CORRECT PN IS SG55325J/883)
-80B UF02-02 . MICROCIRCUIT (V08748) (OPTIONAL)
-80C M38510-13001BEX . MICROCIRCUIT (V08748) (OPTIONAL)
(CORRECT PN IS M38510/13001BEX)
85 JANTX2N3507 . SEMICOND, TRANSISTOR 2
-95A JANTX2N3868 DELETED
100 JANTX2N2222A . SEMICOND, TRANSISTOR 6

Page 10103
24-31-04 May 25/12
4-254
UNITS
4–
105 RNC55H9311BS DELETED
-105A RNC55H9311FS DELETED
-105B RNC55H9311BS DELETED
-105C RNC55H9311FS DELETED
-105D RNC55H9091BS . RESISTOR, 0.1 W, 9.09 K, 0.1% A-C 1
(SELECTED VALUE,
RANGE 7.68 K TO 10.5 K)
-105E RNC55H9091FS . RESISTOR, 0.1 W, 9.09 K, 1% A-C
(OPTIONAL)
-105F RNC55H8061BS . RESISTOR, 0.1 W, 8.06 K 0.1% D-G 1
(SELECTED VALUE, RANGE 5.62 K
TO 10.5 K)
-105G RNC55H8061FS . RESISTOR, 0.1 W, 8.06 K 1% D-G
(OPTIONAL)
-105H RNC55H1102BS . RESISTOR, 0.1 W, 11.3 K, 0.1% H 1
TO 17.0 K)
-105J RNC55H1102FS . RESISTOR, 0.1 W, 11.3 K, 1% H
(OPTIONAL)
-105K RNC55H1002BS . RESISTOR, 0.1 W, 10 K, 0.1% C 1
-105L RNC55H1002FS . RESISTOR, 0.1 W, 10 K, 1% C

(OPTIONAL)
110 RNC55H59R0BS . RESISTOR, 0.1 W, 59 , 0.1% A 1
(SELECTED VALUE,
RANGE 43.2  TO 73.2 )
-110A RNC55H59R0FS . RESISTOR, 0.1 W, 59 , 1% A
(OPTIONAL)
-110B RNC55H71R5BS . RESISTOR, 0.1 W, 71.5 , 0.1% B-H 1
(POST SB4-254-24-09)
-110C RNC55H71R5FS . RESISTOR, 0.1 W, 71.5, 1% B-H
(OPTIONAL)
-115A JANTXV2N2907A . SEMICOND, TRANSISTOR (OPTIONAL) E, H
135 JANTX1N4148-1 . SEMICOND, DIODE 16
137 JANTX1N4148-1 . SEMICOND, DIODE A-D 4
138 JANTX1N4148-1 . SEMICOND, DIODE A-D 1
-138A JANTX1N4153-1 . SEMICOND, DIODE H 1

Page 10104
24-31-04 May 25/12
4-254
UNITS
4–
-140A JANTX1N4370A . SEMICOND, DIODE (OPTIONAL)
145 JANTX1N748A1 . SEMICOND, DIODE A-D 1
-145A JANTX1N748A . SEMICOND, DIODE (OPTIONAL) A-D
146 JANTX1N4153-1 . SEMICOND, DIODE E-H 1
(POST SB4-254-24-09)
147 JANTX1N4153-1 . SEMICOND, DIODE H 1
155 JANTX1N965B1 . SEMICOND, DIODE A-G 1
(CORRECT PN IS JANTX1N965B-1)
-155A JANTX1N965B . SEMICOND, DIODE A-G
(OPTIONAL)
-155B JANTX1N964B1 . SEMICOND, DIODE H 1
(CORRECT PN IS JANTX1N964B-1)
159 M39014-01-1523 . CAP, 100 VDC, 0.0022 F, 10% D-H 2
(POST SB4-254-24-09)
160 M83421-01-6088P . CAP, 30 VDC, 0.01 F, 2% 1

(CORRECT PN IS M83421/01-6088P)
165 M39003-01-2306 . CAP, 35 VDC, 22 F, 10% 1
170 M39003-01-2257 . CAP, 10 VDC, 33 F, 10% 1
175 M39003-01-2523 . CAP, 20 VDC, 2.2 F. 10% 3
180 M39014-02-1415 . CAP, 50 VDC, 1 F, 10% 1
182 M39014-02-1415 . CAP, 50 VDC, 1 F, 10% A-D 1
184 M39014-02-1413 . CAP, 50 VDC, 0.68 F, 10% A-D 1
-184A M39014-01-1535 . CAP, 100 VDC, 0.01 F, 10% E-H 1
185 M39014-02-1413 . CAP, 50 VDC, 0.68 F, 10% 2
186 M39014-01-1535 . CAP, 100 VDC, 0.01 F, 10% H 1

Page 10105
24-31-04 May 25/12
4-254
UNITS
4–
187 M39014-01-1535 . CAP, 100 VDC, 0.01 F, 10% A 1
-187A M39014-01-1553 . CAP, 50 VDC, 0.1 F, 10% B-H 1
188 M39014-01-1553 . CAP, 50 VDC, 0.1 F, 10% C-H 2
190 M39014-02-1358 . CAP, 50 VDC, 0.33 F, 10% A-D 1
-190A M39014-02-1318 . CAP, 50 VDC, 0.33 F, 10% E-H 1
(POST SB4-254-24-09)
195 M39014-01-1541 . CAP, 50 VDC, 0.022 F, 10% A-G 1
-195A M39014-01-1314 . CAP, 200 VDC, 680 PF, 10% H 1
200 M39014-01-1535 . CAP, 100 VDC, 0.01 F, 10% B-D 1
205 M39014-01-1526 . CAP, 100 VDC, 0.0033 F, 10% 2

210 M39014-01-1320 . CAP, 100 VDC, 0.0015 F, 10% 2
215 M39014-01-1317 . CAP, 200 VDC, 0.001 F, 10% 2
217 M39014-01-1317 . CAP, 200 VDC, 0.001 F, 10% A-D 1
220 M39014-01-1541 . CAP, 50 VDC, 0.022 F, 10% 1
225 M39014-01-1305 . CAP, 200 VDC, 220 PF, 10% 6
230 M39014-01-1302 . CAP, 200VDC, 150 PF, 10% 1
231 CA92-01A . CAP, 500 VDC, 0.01 F, 10% (V08748) 1
-231A 151B103K501LEXH . CAP, 500 VDC, 0.01 F, 10% (V65238)
232 M39014-01-1320 . CAP, 100 VDC, 0.0015 F, 10% E-H 1
(POST SB4-254-24-09)

Page 10106
24-31-04 May 25/12
4-254
UNITS
4–
233 RCCS280075-1C . INSULATOR (V19080) D, E, H
(LT73-01, V08748)
(USED UNDER ITEM 231)
(CORRECT PN IS RC-CS280075-1C)
-233A RCCS280075-1V . INSULATOR (V19080) D, E, H 1
(SUPSDS ITEM 233)
(LT73-01, V08748)
(CORRECT PN IS RC-CS280075-1V)
-233B LT73-01 . INSULATOR (V08748) (OPTIONAL)
235 RER60F4R99R . RESISTOR, 5 W, 4.99 K, 1% 2
240 RWR81S5230FR . RESISTOR, 1 W, 523 , 1% 2
242 526700-02 . INSULATOR (V07047) (LT20-2, V08748) 2
245 RWR81S6R81FR . RESISTOR, 1 W, 6.81 , 1% A-D 1
250 RNC55H2611FS . RESISTOR, 0.1 W, 2.61 K, 1% A 1
-250A RNC55H8871FS . RESISTOR, 0.1 W, 8.87 K, 1% B-D 1
-250B RNC55H1622FS . RESISTOR, 0.1 W, 16.2 K, 1% E-H 1
(POST SB4-254-24-09)
255 RCR42G471JS . RESISTOR, 2 W, 470 , 5% 2
270 RCR20G330JS . RESISTOR, 0.5 W, 33 , 5% A-D 2
-270A RLR20C33R0GS . RESISTOR, 0.5 W, 33 , 2% E-H 2
(REPLS ITEM 270B)
-270B RCR20G330JS . RESISTOR, 0.5 W, 33 , 5% E-H
275 RCR20G8R2JS . RESISTOR, 0.5 W, 8.2 , 5% A-D 2
-275A RLR20C8R20GS . RESISTOR, 0.5 W, 8.2 , 2% E-H 2
(REPLS ITEM 275B)
-275B RCR20G8R2JS . RESISTOR, 0.5 W, 8.2 , 5% E-H
280 RCR07G361JS . RESISTOR, 0.25 W, 360 , 5% A-C 2
-280A RLR07G3600GS . RESISTOR, 0.25 W, 360 , 2% H 2
-280B RCR07G361JS . RESISTOR, 0.25 W, 360 , 5% H
(OPTIONAL)
-280C RLR07G3600GS . RESISTOR, 0.25 W, 360 , 2% D-G 2
(REPLS ITEM 280D)
-280D RCR07G361JS . RESISTOR, 0.25 W, 360 , 5% D-G

Page 10107
24-31-04 May 25/12
4-254
UNITS
4–
285 RCR07G563JS . RESISTOR, 0.25 W, 56 K, 5% A-C 1
-285A RLR07C5602GS . RESISTOR, 0.25 W, 56 K, 2% H 1
-285B RCR07G563JS . RESISTOR, 0.25 W, 56 K, 5% H
(OPTIONAL)
-285C RLR07C5602GS . RESISTOR, 0.25 W, 56 K, 2% D-G 1
(REPLS ITEM 285D)
-285D RCR07G563JS . RESISTOR, 0.25 W, 56 K, 5% D-G
290 RCR07G222JS . RESISTOR, 0.25 W, 2.2 K, 5% A-C 2
-290A RLR07C2201GS . RESISTOR, 0.25 W, 2.2 K, 2% H 2
-290B RCR07G222JS . RESISTOR, 0.25 W, 2.2 K, 5% H
(OPTIONAL)
-290C RLR07C2201GS . RESISTOR, 0.25 W, 2.2 K, 2% D-G 2
(REPLS ITEM 290D)
-290D RCR07G222JS . RESISTOR, 0.25 W, 2.2 K, 5% D-G
-295A RLR07C82R0GS . RESISTOR, 0.25 W, 82 , 2% H 2
(OPTIONAL)
-295C RLR07C82R0GS . RESISTOR, 0.25 W, 82 , 2% D-G 2

(REPLS ITEM 295D)
(OPTIONAL)
(REPLS ITEM 300D)
(OPTIONAL)
(REPLS ITEM 305D)

Page 10108
24-31-04 May 25/12
4-254
UNITS
4–
-310A RLR07C2200GS . RESISTOR, 0.25 W, 220 , 2% H 2
(OPTIONAL)
-310C RLR07C2200GS . RESISTOR, 0.25 W, 220 , 2% D-G 2
(REPLS ITEM 310D)
315 RCR07G180JS . RESISTOR, 0.25 W, 18 , 5% A-C 2
(OPTIONAL)
(REPLS ITEM 315D)
(OPTIONAL)

(REPLS ITEM 320D)
-325A RLR07G1303GS . RESISTOR, 0.25 W, 130 K, 2% D, E, H 1
-325B RCR07G134JS . RESISTOR, 0.25 W, 130 K, 5% D, E, H
(OPTIONAL)
-325C RLR07G1303FS . RESISTOR, 0.25 W, 130 K, 1% F, G 1
(REPLS ITEM 325D)
-325D RCR07G134JS . RESISTOR, 0.25 W, 130 K, 5% F, G
-330A RLR07C2701GS . RESISTOR, 0.25 W, 2.7 K, 2% D 2
-330B RLR07C2701GR . RESISTOR, 0.25 W, 2.7 K, 2% D-H
(OPTIONAL)
-330C RLR07C2701GS . RESISTOR, 0.25 W, 2.7 K, 2% E-G 2
(REPLS ITEM 330D)
-330D RCR07G272JS . RESISTOR, 0.25 W, 2.7 K, 5% E-G
-330E RLR07C2701GS . RESISTOR, 0.25 W, 2.7 K, 2% H 2
(SUPSDS ITEM 330F)
-330F RCR07G272JS . RESISTOR, 0.25 W, 2.7 K, 5% H
(SUPSD BY ITEM 330E)

Page 10109
24-31-04 May 25/12
4-254
UNITS
4–
(OPTIONAL)
-335C RLR07C1002FS . RESISTOR, 0.25 W, 10 K, 1% D-G 4
(REPLS ITEM 335D)
-336B RLR07C1002FS . RESISTOR, 0.25 W, 10 K, 1% D-G 1
(REPLS ITEM 336C)
-336C RCR07G103JS . RESISTOR, 0.25 W, 10 K, 5% D-G
337 RLR07C1601GS . RESISTOR, 0.25 W, 1.6 K, 2% H 1
-337A RCR07G471JS . RESISTOR, 0.25 W, 470 , 5% A-C 1
-337B RLR07C4700GS . RESISTOR, 0.25 W, 470 , 2% D-G 1
(REPLS ITEM 337C)
-337C RCR07G471JS . RESISTOR, 0.25 W, 470 , 5% D-G
340 RCR07G102JS . RESISTOR, 0.25 W, 1 K, 5% A-D 1

(SUPSDS ITEM 341B)
-341C RLR07C1001FS . RESISTOR, 0.25 W, 1 K, 1% D 2
(SUPSDS ITEM 341D)
-341D RCR07G102JS . RESISTOR, 0.25 W, 1 K, 5% D
-341E RLR07C1001FS . RESISTOR, 0.25 W, 1 K, 1% E-G 2
(REPLS ITEM 341F)
-341F RCR07G102JS . RESISTOR, 0.25 W, 1 K, 5% E-G
345 RCR07G105JS . RESISTOR, 0.25 W, 1 M, 5% A 1
(OPTIONAL)
(REPLS ITEM 350D)

Page 10110
24-31-04 May 25/12
4-254
UNITS
4–
-355A RCR07G471JS . RESISTOR, 0.25 W, 470 , 5% H
(OPTIONAL)
-355B RLR07C4700GS . RESISTOR, 0.25 W, 470 , 2% H 7
(REPLS ITEM 355D)
(OPTIONAL)
(REPLS ITEM 360D)
-365A RLR07C1003FS . RESISTOR, 0.25 W, 100 K, 1% D 1
(REPLS ITEM 365B)
-365B RCR07G104JS . RESISTOR, 0.25 W, 100 K, 5% D

(OPTIONAL)
(REPLS ITEM 370D)
-375A RLR07C4702GS . RESISTOR, 0.25 W, 47 K, 2% D-G 1
(REPLS ITEM 375B)
-375B RCR07G473JS . RESISTOR, 0.25 W, 47 K, 5% D-G
-375C RLR07C4702GS . RESISTOR, 0.25 W, 47 K, 2% H 1
(SUPSDS ITEM 375D)
-375D RCR07G473JS . RESISTOR, 0.25 W, 47 K, 5% H

Page 10111
24-31-04 May 25/12
4-254
UNITS
4–
(OPTIONAL)
(REPLS ITEM 380D)
(OPTIONAL)
(REPLS ITEM 385D)
-386A RNC55H4752FS . RESISTOR, 0.1 W, 47.5 K, 1% E-H 1
(POST SB4-254-24-09)
-386B RLR07C1800GS . RESISTOR, 0.25 W, 180 , 2% D 1
(REPLS ITEM 386C)

-386C RCR07G181JS . RESISTOR, 0.25 W, 180 , 5% D
390 RCR07G8R2JS . RESISTOR, 0.25 W, 8.2 , 5% A-C 2
-390B RCR07G8R2JS . RESISTOR, 0.25 W, 8.2 , 5% H
(OPTIONAL)
-390C RLR07C10R0FS . RESISTOR, 0.25 W, 10 , 1% D 2
(REPLS ITEM 390D)
-390D RCR07G8R2JS . RESISTOR, 0.25 W, 8.2 , 5% D
-390E RLR07C8R20GM . RESISTOR, 0.25 W, 8.2 , 2% E 2
(REPLS ITEMS 390F AND 390G)
-390F RCR07G8R2JS . RESISTOR, 0.25 W, 8.2 , 5% E
-390G RLR07C8R20GS . RESISTOR, 0.25 W, 8.2 , 2% E
-390H RLR07C8R20GS . RESISTOR, 0.25 W, 8.2 , 2% F, G 2
(REPLS ITEM 390J)
-390J RCR07G8R2JS . RESISTOR, 0.25 W, 8.2 , 5% F, G
(REPLD BY ITEM 390H)

Page 10112
24-31-04 May 25/12
4-254
UNITS
4–
(OPTIONAL)
-395C RLR07C1201GS . RESISTOR, 0.25 W 1.2 K, 2% D-G 1
(REPLS ITEM 395D)
400 RCR07G823JS . RESISTOR, 0.25 W, 82 K, 5% A 1
-400A RLR07C8202GR . RESISTOR, 0.25 W, 82 K, 2% B-D
(OPTIONAL)
-400B RLR07C8202GS . RESISTOR, 0.25 W, 82 K, 2% B-D 1
(OPTIONAL)
(REPLS ITEM 405D)

-406A RLR07C3300GS . RESISTOR, 0.25 W, 330 , 2% E-H 1
(POST SB4-254-24-09)
-406B RLR07C2202GS . RESISTOR, 0.25 W, 22 K, 2% D 1
(REPLS ITEM 406C)
-406C RCR07G223JS . RESISTOR, 0.25 W, 22 K, 5% D
410 RCR07G565JS . RESISTOR, 0.25 W, 5.6 M, 5% A-C 1
-410A RLR07C5604GS . RESISTOR, 0.25 W, 5.6 M, 2% D 1
(REPLS ITEM 410C)
-410B RLR07C5604GR . RESISTOR, 0.25 W, 5.6 M, 2% D
(OPTIONAL)
-410C RCR07G565JS . RESISTOR, 0.25 W, 5.6 M, 5% D
425 RNC55H33R2FS . RESISTOR, 0.1 W, 33.2 , 1% A 1
-425A RNC55H71R5BS . RESISTOR, 0.1 W, 71.5 , 0.1% B-H 1
(POST SB4-254-24-09)
-425B RNC55H71R5FS . RESISTOR, 0.1 W, 71.5 , 1% B-H 1
(OPTIONAL)

Page 10113
24-31-04 May 25/12
4-254
UNITS
4–
-430A RNC55H4641BS DELETED
-430C RNC55H5111BS . RESISTOR, 0.1 W, 5.11 K, 0.1% C 1
-430D RNC55H5111FS . RESISTOR, 0.1 W, 5.11 K, 1% C
(OPTIONAL)
-430E RNC55H4641BS DELETED
-430F RNC55H1652FS . RESISTOR, 0.1 W, 16.5 K, 1% E-G 1
(POST SB4-254-24-09)
-430G RNC55H7682FS . RESISTOR, 0.1 W, 76.8 K, 1% H 1
-430H RNC55H4531BS . RESISTOR, 0.1 W, 4.53 K, 0.1% B, C 1
TO 6.49 K)
-430J RNC55H4531FS . RESISTOR, 0.1 W, 4.53 K, 1% B, C
(OPTIONAL)
-430K RNC55H1102BS . RESISTOR, 0.1 W, 11 K, 0.1% D 1
(SELECTED VALUE,
RANGE 2 KTO 20 K)
-430L RNC55H1102FS . RESISTOR, 0.1 W, 11 K, 1% D
(OPTIONAL)
435 RNC55H4750FS . RESISTOR, 0.1 W, 475 , 1% 1

-440A RNC55H9531FS . RESISTOR, 0.1 W, 9.53 K, 1% B-D 1
-440B RNC55H1102FS . RESISTOR, 0.1 W, 11 K, 1% E-H 1
(POST SB4-254-24-09)
-440C RNC55H1152FS . RESISTOR, 0.1 W, 1105 K, 1% H
(OPTIONAL)
445 RNC55H2740FS . RESISTOR, 0.1 W, 274 , 1% A-D 1
-445A RNC55H4120FS . RESISTOR, 0.1 W, 412 , 1% E-H 1
450 RNC55H1001BS . RESISTOR, 0.1 W, 1 K, 0.1% A, B 1
-450A RNC55H1001FS . RESISTOR, 0.1 W, 1 K, 1% A, B
(OPTIONAL)
-450C RNC55H1001FS . RESISTOR, 0.1 W, 1 K, 1% C-G 1
-450D RNC55H1001BS . RESISTOR, 0.1 W, 1 K, 0.1% C-G
(OPTIONAL)
-450E RNC55H4641FS . RESISTOR, 0.1 W, 4.64 K, 1% H 1

Page 10114
24-31-04 May 25/12
4-254
UNITS
4–
455 RLR07C2701GS . RESISTOR, 0.25 W, 2.7 K, 2% A-D 1
-455A RLR07C2701GR . RESISTOR, 0.25 W, 2.7 K, 2%
(OPTIONAL)
-455B RLR07C2701GS . RESISTOR, 0.25 W, 2.7 K, 2% E-G 1
(REPLS ITEM 455C)
-455C RCR07G272JS . RESISTOR, 0.25 W, 2.7 K, 5% E-G
-455D RLR07C2701GS . RESISTOR, 0.25 W, 2.7 K, 2% H 1
(SUPSDS ITEM 455E)
-455E RCR07G272JS . RESISTOR, 0.25 W, 2.7 K, 5% H
(SUPSD BY ITEM 455D)
-460D RNC55H4122BS . RESISTOR, 0.1 W, 4.12 K, 0.1% A 1
(SELECTED RANGE, 18.7 K
TO 63.4 K)
-460E RNC55H4122FS . RESISTOR, 0.1 W, 4.12 K, 1% A
(OPTIONAL)
-460F RNC55H6193BS . RESISTOR, 0.1 W, 619 K0.1% B-D 1

(SELECTED VALUE, RANGE 10 K
TO 1.21 M)
-460G RNC55H6193FS . RESISTOR, 0.1 W, 619 K1% B-D
(OPTIONAL)
-465D RNC55H6491BS . RESISTOR, 0.1 W, 6.49 K, 0.1% A 1
(SELECTED VALUE, RANGE 3.83 K
TO 9.09 K)
-465E RNC55H6491FS . RESISTOR, 0.1 W, 6.49 K, 1% A
(OPTIONAL)
-465F RNC55H6193BS . RESISTOR, 0.1 W, 619 K0.1% B-D 1
(SELECTED VALUE, RANGE 12.7 K
TO 1.21 M)
-465G RNC55H6193FS . RESISTOR, 0.1 W, 619 K1% B-D
(OPTIONAL)

Page 10115
24-31-04 May 25/12
4-254
UNITS
4–
470 2-36151-2 . LUG, CRP, INSLD (V00779) A-G
(TE12-1, V08748)
-470A MS25036-102 . LUG, CRP, INSLD A-G 1
(SUPSDS ITEM 470B)
(REPLS ITEM 470)
-470B MS25036-101 . LUG, CRP, INSLD A-G
-470C TE12-1 . LUG, CRP, INSLD (V08748) A-G
(OPTIONAL)
475 RLR07C8202GR . RESISTOR, 0.25 W, 82 K, 2% B-D
(OPTIONAL)
-475A RLR07C8202GS . RESISTOR, 0.25 W, 82 K, 2% B-D 1
480 RLR07C4702GS . RESISTOR, 0.25 W, 47 K, 2% E-G 1
(POST SB4-254-24-09)
(REPLS ITEM 480A)
-480A RCR07G473JS . RESISTOR, 0.25 W, 47 K, 5% E-G
(REPLD BY ITEM 480)
-480B RLR07C4702GS . RESISTOR, 0.25 W, 47 K, 2% H 1
(SUPSDS ITEM 480C)
-480C RCR07G473JS . RESISTOR, 0.25 W, 47 K, 5% H

485 RNC55H1242FS . RESISTOR, 0.1 W, 12.4 K, 1% E-H 1
(POST SB4-254-24-09)
495 10-915-3-04 . TERMINAL (V18310) (TM16-18T, V08748) E-G 1
(POST SB4-254-24-09)
-495A 10-915-3-05 . TERMINAL (V18310) (OPTIONAL) E-G
-495B TM16-18T . TERMINAL (V08748) (OPTIONAL) E-G
500 4-254260-01 . NETWORK, RES CAP DIODE (V08748) E-G 1
(POST SB4-254-24-09)
510 M39003-01-2977 . CAP, 10VDC, 33 F, 10% H 1
515 RLR07C1000GS . RESISTOR, 0.25 W, 100 , 2% H 1
520 RLR07C1001GS . RESISTOR, 0.25 W, 1 K, 2% H 1
(SUPSDS ITEM 520A)
-520A RCR07G102JS . RESISTOR, 0.25 W, 1 K, 5% H
(SUPSD BY ITEM 520)

Page 10116
24-31-04 May 25/12
4-254
UNITS
4–
525 M39003-01-1529 . CAP, 100VDC, 0.0047 F, 10% H
-525A M39014-01-1529 . CAP, 100VDC, 0.0047 F, 10% H 1
(SUPSDS ITEM 525)
530 RLR07C6200GS . RESISTOR, 0.25 W, 620 , 2% H 1
-530A RCR07G471JS . RESISTOR, 0.25 W, 470 , 5% A-C 1
-530B RLR07C4700GS . RESISTOR, 0.25 W, 470 , 2% D-G 1
(REPLS ITEM 530C)
-530C RCR07G471JS . RESISTOR, 0.25 W, 470 , 5% D-G
535 RLR07C10R0GS . RESISTOR, 0.25 W, 10 , 2% H 1

Page 10117
24-31-04 May 25/12
4-254
BLANK
THIS PAGE
INTENTIONALLY
24-31-04
Page 10118
May 25/12
4-254

Page 10119
24-31-04 May 25/12
4-254

Circuit Card Assembly A2A1 (Configuration 4-254411-01/-02/4-254511-01)
Page 10120
24-31-04 May 25/12
4-254
UNITS
5–
10 RCR07G2R7JS . RESISTOR, 0.25 W, 2.7 , 5% 2
15 M39014-01-1553 . CAPACITOR, 50 VDC, 0.1 F, 10% 2
20 1299B5 . TERMINAL, NON-INSULATED (V81312) D 2
(TM40-02, V08748)
(CORRECT PN IS 1299B-5)
-20A TM40-02 . TERMINAL, NON-INSULATED (V08748) D
(OPTIONAL)
-25A CR402-5420TX . SEMICOND, DIODE (OPTIONAL)
35 TF50-362-01 . TRANSFORMER (V08748) C 2
ATTACHING PARTS
-36 MS51957-2 . SCREW 2
-37 MS15975-802 . WASHER, FLAT
(SUPSD BY ITEM 37A)
-37A MS15795-802 . WASHER, FLAT 2
(SUPSDS ITEM 37)
***
40 TF50-277-01 . TRANSFORMER (V08748) 2
55 M55302-62A20S . CONNECTOR, P1 C 1
(CORRECT PN IS M55302/62-A20S)
-55A WTAX20SECJTA . CONNECTOR, P1 (V10400) (OPTIONAL) C
(CN73-12, V08748)
-55B CN73-12 . CONNECTOR, P1 (V08748) (OPTIONAL) C
ATTACHING PARTS
80 MS51957-26 . SCREW A, C, D 1
81 MS35338-136 . WASHER, LOCK A, C, D 1
82 MS15975-805 . WASHER, FLAT A, C, D
(SUPSD BY ITEM 82A)
-82A MS15795-805 . WASHER, FLAT A, C, D 1
(SUPSDS ITEM 82)
***

Page 10121
24-31-04 May 25/12
4-254
UNITS
5–
85 MS77068-2 . LUG B 3
-85A 1902 . LUG (V73734) (OPTIONAL) B
(LU11-1, V08748)
-85B MS77068-2 . LUG A, C, D 2
-85C 1902 . LUG (V07047) (OPTIONAL) A, C, D
(LU11-1, V08748)
-85D LU11-1 . LUG (OPTIONAL)
ATTACHING PARTS
95 MS51957-26 . SCREW B 3
100 MS35338-136 . WASHER, LOCK B 3
101 MS15795-805 . WASHER, FLAT B 3
102 MS51957-26 . SCREW A, C, D 2
103 MS35338-136 . WASHER, LOCK A, C, D 2
104 MS15795-805 . WASHER, FLAT A, C, D 2
***
105 PLC1MS4 . TIE, CABLE (V06383) (CC16-01, V08748) 1
(CORRECT PN IS PLC1M-S4)
-105A CC16-01 . TIE, CABLE (V08748) (OPTIONAL)
ATTACHING PARTS
110 MS51957-21 . SCREW 1

115 MS35649-244 . NUT 1
***
-120 4-254411-01-900 . ASSY, TERMINAL BOARD (V08748) A 1
-120A 4-254311-01-900 . ASSY, CONNECTOR HARNESS B 1
(V08748)
-120B 4-254411-02-900 . ASSY, HARNESS (V08748) D 1

Page 10122
24-31-04 May 25/12

4-254 Rev 16 Apr 2015

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4-254 Rev 16 Apr 2015

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REVISION TRANSMITTAL

REVISION NUMBER 16, DATED APR 17/15

Page No. Description of Change Effectivity

Title Page Updated. All

COMPONENT MAINTENANCE MANUAL

CRANE AEROSPACE & ELECTRONICS PROPRIETARY

REV ISSUE INSERT INSERTED REV ISSUE INSERT INSERTED

24-31-04 May 25/12

TEMP INSERTED REMOVED

24-31-04-1 Mar 12/15 Apr 17/15

24-31-04-2 Mar 12/15 Apr 17/15

RECORD OF TEMPORARY REVISIONS

RECORD OF TEMPORARY REVISIONS

SERVICE BULLETIN/ DATE BULLETIN

4-254-24-09 1 Feb 15/89

4-254-24-10 0 Jun 15/91

4-254-24-11 1 Feb 1/95

4-254-24-12 2 Feb 12/97

4-254-24-13 2 Mar 30/04

Service Bulletin 4-254-24-09, Revision 1

Battery Charger as PN 4-254-03 (Boeing ST282T002-4).

Service Bulletin 4-254-24-10, Revision 0

Service Bulletin 4-254-24-11, Revision 1

SERVICE BULLETIN LIST

Service Bulletin 4-254-24-13, Revision 2

SERVICE BULLETIN LIST

RECORD OF ROR-1 Apr 17/15 ROR-2 Blank

RECORD OF RTR-1 Apr 17/15 RTR-2 Blank

SERVICE BULLETIN SBL-1 May 25/12 SBL-2 May 25/12

LIST OF FIGURES LOF-1 May 25/12 LOF-2 Blank

LIST OF TABLES LOT-1 May 25/12 LOT-2 Blank

INTRODUCTION INT-1 Apr 17/15 INT-2 May 25/12

LIST OF EFFECTIVE PAGES

CLEANING 4001 Nov 14/14 4002 Blank

FITS AND 8001 May 25/12 8002 Blank

LIST OF EFFECTIVE PAGES

LIST OF EFFECTIVE PAGES

LIST OF EFFECTIVE PAGES

DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

TESTING AND FAULT ISOLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001

B. Pre-Performance Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1005

SCHEMATICS AND WIRING DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2001

10. A1 Input Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6010

2. Recommended Materials, Tools, fixtures and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001

FITS AND CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001

SPECIAL TOOLS, FIXTURES, AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001

DESCRIPTION AND OPERATION

TESTING AND FAULT ISOLATION

SCHEMATICS AND WIRING DIAGRAMS

ILLUSTRATED PARTS LIST

DESCRIPTION AND OPERATION

TESTING AND FAULT ISOLATION

FITS AND CLEARANCES

SPECIAL TOOLS, FIXTURES, AND EQUIPMENT

CAUTION: UNLESS OTHERWISE NOTED, ALL INTEGRATED CIRCUITS ON CIRCUIT CARDS

NOTE: All voltages are dc unless otherwise stated.

Product Support Representative

WARNING: WARNINGS IDENTIFY MATERIALS, PROCESSES, METHODS, PROCEDURES, OR

NOTE: Notes identify or add important data.

Use of the Illustrated Parts List is explained in an introduction to that section.

Testing and Fault Isolation Verified 12/15/00

Acronyms and abbreviations are listed on the next page.