SAFT Battery Maintenance Manual

(F6177) 12 rue Sadi Carnot - 93170 Bagnolet - France Tél. (33) 1 49 93 19 18 - Fax: (33) 1 49 93 19 56

COMPONENT MAINTENANCE MANUAL WITH WITH ILLUST ILL USTRATED RATED PA PA RTS RTS LIS L IST T

AIRCRA A IRCRAFT FT BA B A TTERY 20VRED seri 20VRED serie es 804745 804747 804748 804749 804751 806653

Initial issue: Jun 02/2008

24-30-17

Page 1 Revision n°. 2 Feb 18/2015

COMPONENT MAINTENANCE MANUAL 20VRED

PAGE INTENTIONALLY LEFT BLANK

24-30-17

BLANK



24-30-17

BLANK


RECORD OF REVISIONS Rev. n°

Issue date

1 2

Inserted Dat e

By

oct 29/2010

oct 29/2010

Saft

feb 18/2015

feb 18/2015

Saft

Rev. n°

Issue date

24-30-17

Inserted Dat e

By

ROR Page 1 Feb 18/2015



24-30-17

BLANK


RECORD OF TEMPORARY REVISIONS Temp rev. n°

Issue date

Inserted Date

Removed By

Date

24-30-17

By

Page n°

RTR Page 1 Feb 18/2015



24-30-17

BLANK


SERVICE BULLETIN LIST Service bul letin Number

Rev.

Incorporation into CMM Date

Title

Rev.

24-30-17

SBL Page 1 Feb 18/2015



24-30-17

BLANK

SERVICE BULLETIN LIST

COMPONENT MAINTENANCE MANUAL 20VRED 1 Feb 18/2015 TESTING AND FAULT 1001 2 Blank ISOLATION 1002 1003 1 Feb 18/2015 1004 2 Blank SCHEMATIC AND 2001 1 Feb 18/2015 WIRING DIAGRAMS 2002 2 Blank 2003 2004 1 Feb 18/2015 2005 2 Blank 2006

LIST OF EFFECTIVE PAGES

1 2

Feb 18/2015 Feb 18/2015

DISASSEMBLY

3001 3002

Feb 18/2015 Feb 18/2015

TABLE OF CONTENT

1 2 3 4

Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015

CLEANING

4001 4002

Feb 18/2015 Blank

LIST OF ILLUSTRATIONS

1 2

Feb 18/2015 Blank

INTRODUCTION

1 2 3 4 5 6 7 8

Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015

INSPECTION/CHECK 5001 5002 5003 5004 5005 5006

Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015

DESCRIPTION AND OPERATION

1 2

Feb 18/2015 Blank

TITLE PAGE

RECORD OF REVISIONS RECORD OF TEMPORARY REVISIONS

24-30-17

Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Blank

LEP Page 1 Feb 18/2015

REPAIR

COMPONENT MAINTENANCE MANUAL 20VRED 6001 Feb 18/2015 DETAILED 6002 Feb 18/2015 PARTS LIST

ASSEMBLY

7001 7002

Feb 18/2015 Blank

FITS AND CLEARANCES

8001 8002

Feb 18/2015 Blank

SPECIAL TOOLS, 9001 FIXTURES, 9002 EQUIPMENT AND CONSUMABLES

Feb 18/2015 Blank

ILLUSTRATED PARTS LIST

10001 10002

Feb 18/2015 Blank

INTRO IPL

10003 10004 10005 10006 10007 10008

Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Blank

ALPHA NUMERICAL INDEX

10009 10010

Feb 18/2015 Blank

10011 10012 10013 10014 10015 10017 10018 10019 10020 10021 10022 10023 10024

Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Feb 18/2015 Blank

STORAGE (INCLU15001 DING TRANSPORTA- 15002 TION) 15003 15004

Feb 18/2015 Feb 18/2015 Feb 18/2015 Blank

24-30-17

LEP Page 2 Feb 18/2015


TABLE OF CONTENT RECORD OF REVISIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -ROR-1 RECORD OF TEMPORARY REVISIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - RTR-1 SERVICE BULLETIN LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SBL -1 INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-1 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-1 A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-1 B. How to Use the Manual - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-1 C. Associated Publications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-1 D. Revision and updating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-1 E. CMM Page Blocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-2 F. Measurements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-5 G. Units of Measure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-6 H. Measurement Conversion Table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-7 I. Temperature Conversion Table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-7 J. Abbreviations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-7 K. Verifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-8 L. Definition - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-8 M. Disposal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-8 DESCRIPTION AND OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 1. Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 B. Characteristics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 C. Detailed description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 TESTING AND FAULT ISOLA TION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1001 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1001 A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1001 2. Testing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1001 A. Reason for the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1001 B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1001 C. Job set-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1001 D. Maintenance guideline - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1002 3. Charge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1002 A. Reason of the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1002 B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1002 C. Job set up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1002 D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1003 E. Close-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1003 4. Discharge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1003 A. Reason of the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1003 B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1003 C. Job set up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1003 D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1004 SCHEMATIC AND WIRING DIAGRAMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2001

24-30-17

TOC Page 1 Feb 18/2015


TABLE OF CONTENT 1. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2001 A. 804751 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2001 B. 804747 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2002 C. 804748 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2003 D. 804749 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2004 E. 804745 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2005 F. 806653 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2006 DISASSEMBL Y - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001 A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001 B. Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001 C. Risks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001 D. Safety measure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001 2. Disassembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3002 A. Reason for the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3002 B. Consumables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3002 C. Job set up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3002 D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3002 E. Close up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3002 CLEANING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001 A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001 2. Cleaning of a unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001 A. Reason for the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001 B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001 C. Job set up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001 D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001 E. Close up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001 INSPECTION/CHECK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001 A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001 2. Maintenance steps in workshop- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001 A. Reason for the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001 B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001 C. Job set-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001 D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5002 E. General overhaul (minimum 1 per year) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5002 REPAIR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6001 1. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6001 2. Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6001 A. Special tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6001 B. Standard tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6001 C. Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6001 3. Repairs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6001

24-30-17



TABLE OF CONTENT REPAIR N°1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6002 4. Changing the battery pack (040) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6002 A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6002 B. Detailed procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6002 ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001 A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001 2. Assembly procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001 A. Reason for the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001 B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001 C. Job set-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001 D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001 E. Close up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001 FITS AND CLEA RANCES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8001 1. Torque table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8001 A. Torque table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8001 SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMMAB LES - - - - - - - - - - - - - - - 1. Special tools, fixtures and equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. Special tools table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2. Consumables material - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. Consumable materials table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. How to Use the illustrated Parts List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Numerical Index (NI) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. Detailed Parts List (DPL) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E. Updating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

9001 9001 9001 9001 9001

10003 10003 10003 10003 10003 10003 10005

VENDOR LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10007 AL PHA NUMERICAL INDEX - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10009 DETAILED PARTS LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10011 STORAGE (INCLUDING TRANSPORTATION) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Storage room - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Temperature conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2. Stand-by storage procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. Reason for the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Job set up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

24-30-17

15001 15001 15001 15001 15001 15001 15001 15001 15001 15001


COMPONENT MAINTENANCE MANUAL 20VRED E. End of the stand-by storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15002 3. Long term storage procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15002 A. Reason for the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15002 B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15002 C. Joob set up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15002 D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15003 E. End of the long term storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15003 4. Transportation procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15003 A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15003

24-30-17

Page 4 Feb 18/2015


LIST OF ILLUSTRATIONS INTRO-1 2001 2002 2003 2004 2005 10001 10002 10003 10004 10005 15001

Recyclable Product - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 804751 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2001 804747 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2002 804748 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2003 804749 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2004 804745 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2005 804751 battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10012 804747 battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10014 804748 battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10016 804749 battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10018 804745 battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10020 Short term storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15002

24-30-17

LOI Page 1 Feb 18/2015



24-30-17

BLANK


INTRODUCTION TASK 24-30-17-871-801-A01 1. Introduction A. General (1) This component maintenance manual (CMM) agrees with the Air Transport Association (ATA), and it is written in AECMA Simplified English (European Association of Aerospace Industries). (2) This CMM gives the procedures necessary to do simple checks and replacement of parts and components. It also gives the procedures for maintenance. The maintenance procedures given in this CMM are only for approved persons with the necessary skills. (3) This CMM gives the shop maintenance procedures of the component. (4) This CMM uses the identification of the tasks and subtasks which is defined in the Maintenance Task Oriented Support System (MTOSS). The maintenance tasks and other data have special MTOSS numbers for the use of Electronic Data Processing (EDP). The user of the manual can ignore the MTOSS numbers. (5) This manual contains: - the technical data for the component, - the maintenance and repair procedures for the component, - an Illustrated Parts List (IPL) with the data for the component parts. The parts are identified in all the Page Blocks of the manual, by the IPL Figure and the item number. (6) A check of the DISASSEMBLY, TESTING and ASSEMBLY procedures in the workshop. (7) Battery disassembly, except when done to change the battery pack voids the warranty. B. How to Use the Manual (1) Make sure the manual contains the applicable data for your component. Look for the part number on the Title Page. (2) To identify a part or to find a part number, refer to the IPL, which has an Introduction to show the procedure. (3) You must use the instructions in this manual, for all the maintenance steps of a component. Read all the applicable WARNINGS and CAUTIONS before you do the work on the component. (4) When you use consumable materials, these materials are identified by a code number which is listed in the Consumable Materials Table. (5) When you use special tools, these tools are identified by a code number which is listed in the Special Tools Table. (6) For the tightening torque values of the parts, refer to the Table of Tightening Torques. C. Associated Publications Not applicable. D. Revision and updating This manual is revised periodically and may be the subject of update which refers to modifications made on the equipment. Detailed instructions relative to the insertion of withdrawal of pages accompany each update.

24-30-17

INTRO Page 1 Feb 18/2015

COMPONENT MAINTENANCE MANUAL 20VRED E. CMM Page Blocks (1) The information for each component in the CMM is divided into specific Page Blocks. Each Page Block has its own specified subject matter and its own specified page numbering. These Page Blocks have these titles: PAGEBLOCKS

PAGENUMBER

Description and Operation

0001 to 0999

Testing and Fault Isolation

1001 to 1999

Schematics and Wiring Diagrams

2001 to 2999

Disassembly

3001 to 3999

Cleaning

4001 to 4999

Inspection/Check

5001 to 5999

Repair

6001 to 6999

Assembly

7001 to 7999

Fits and Clearances

8001 to 8999

Special Tools, Fixtures, Equipment and Consumables

9001 to 9999

ACTUAL VERIFICATIONS

Illustrated Parts List

10001 to 10999

Special Procedure

11001 to 11999

Not applicable

Removal

12001 to 12999

Not applicable

Installation

13001 to 13999

Not applicable

Servicing

14001 to 14999

Not applicable

Storage (including Transportation)

15001 to 15999

Rework (Service Bulletin Instructions)

16001 to 16999

DATE

BY

Not applicable

(2) Description and Operation This Page Block gives general data. It gives a mechanical description and an electrical description. It gives a description of the configuration and operation of the component. (3) Testing and Fault Isolation (a) It contains special tests and procedures which you must do to find the condition of a component. The general test procedure is given in the FAULT ISOLATION TABLE. For each test, this table refers to a special procedure which gives all the parameters which you

24-30-17


COMPONENT MAINTENANCE MANUAL 20VRED must set. It also gives all the parameters for which you must do a check. The block diagram (refer to task 24-30-17-700-801-A01 ) gives the correct procedure to follow as necessary. (b) The pressure values in the tests are gage-pressure values. (c) Before you use any of the measuring instruments, make sure that they are in correct operating condition and that they are calibrated. (d) Do a check for pneumatic system tightness, if this is applicable. (e) You must do the tests in a room at ambient temperature +23 °C ± 5 °C (73 °F ± 9 °F). (4) Schematic and Wiring Diagrams This Page Block contains all the schematic diagrams and the wiring and interconnecting diagrams of the cards. It also contains the diagrams of: - chassis wiring, modules, and sub-assemblies - external connector interconnections in the component. (5) Disassembly (a) This Page Block gives step-by-step disassembly instructions in a correct sequence, and it refers to the figure item numbers from the IPL illustration(s), when they are applicable. Identify the type of fault, to know how much the extent of disassembly is necessary (do this to prevent disassembly/reassembly work that is not necessary). The procedure given below is when full disassembly is necessary. (b) Put the component on a clean workbench, in a dust-free and moisture-free room. Move all the parts carefully, and prevent corrosion and impact damage to them after disassembly. NOTE: Discard the washers, the nuts and the screws during disassembly if they are damaged. (6) Cleaning (a) This Page Block gives a step-by-step description of the cleaning operations for the component and its parts. (b) Always use the recommended procedures for the component parts of the unit. (7) Inspection / Check (a) This Page Block gives the full check procedures which are necessary during shop maintenance. (b) Discard all the defective parts if the document does not give a repair procedure. (c) Do all the inspections/checks on the cleaned parts. (8) Repair This Page Block contains the full repair procedures and specifications which are necessary to repair a worn or damaged part. As specified in the INSPECTION/CHECK section, you must reject the defective parts if the document does not give a repair procedure. Replace the defective parts with new parts.

24-30-17


COMPONENT MAINTENANCE MANUAL 20VRED (9) Assembly (a) This Page Block gives step-by-step assembly instructions in a correct sequence, which refer to the figure item numbers from the IPL illustration(s), if applicable. (b) Put the component on a clean workbench, in a dust-free and moisture-free room. More all the parts carefully, and prevent corrosion and impact damage to them. (c) Be sure to remove the storage protection coating from all the new parts before assembly. Clean the new part if necessary. (10) Fits and Clearances (a) This Page Block gives a table and some figures which gives the fits and clearances data and the torque values for assembly. It also gives the permitted wear for in-service / service, and the manufacturer’s design wear-tolerances. (b) Fits and Clearances Table 1 The identifiers in column (1) show the location of the clearance or the dimension that you must measure.. 2 The identifiers in column (2) identify the parts in the IPL (Figure + Item number). 3 Column (3) gives the initial manufacturing dimensions and clearances. 4 In-service Wear Limits (Columns 4). a The maximum limits are the maximum wear limits. If the part is in these limits then it is serviceable. b If the parts have more wear than the specified limits, you must repair or replace them. (c) Torque Values 1 All torque values in this manual are shown in the Table of Tightening Torques. The parts are identified by the figure number and the item number of the IPL.

(d) Spring Data 1 The technical data for all springs used in the unit are shown in the Table of Spring Data. The parts are identified by the figure number and the item number of the IPL. (11) Special Tools, Fixtures, Equipment and Consumables (a) This Page Block shows all the special tools, the fixtures, the equipment and the consumables which are necessary to do the maintenance actions which are given in the other page blocks. (b) All the items shown are identified in this manual by a standard code number: Txx for Tools, Fixtures and Equipment and Mxx for Consumable Materials. (12) Illustrated Parts List This Page Block contains the full list of all the parts of the component (For the detailed description, refer to the IPL INTRO). (13) Special Procedures This Page Block contains the tasks which are given in other Page Blocks of the manual, but which are necessary because of other maintenance tasks. The tasks are self-contained repairs or preventive maintenance.

24-30-17


COMPONENT MAINTENANCE MANUAL 20VRED (14) Removal This Page Block gives the procedure for the removal of modules/sub-assemblies from complex modular components. (15) Installation This Page Block gives the procedure for the installation of modules/sub-assemblies in complex modular components. (16) Servicing This Page Block gives the self-contained tasks which are necessary because of other maintenance tasks. (17) Storage This Page Block gives the requirements for preparation for transportation, for special handling, for packaging, for storage and for preservation: these requirements are for the component after assembly or test. (18) Rework This Page Block gives the rework procedures which are necessary for in-service components. F. Measurements (1) The measurements which are given in this manual come from the original manufacturing drawings. (2) This CMM uses the “Systeme International” (S.I.) units for quantities and values. It also gives the imperial units in parentheses.

24-30-17


COMPONENT MAINTENANCE MANUAL 20VRED G. Units of Measure (1) I.S. Units A Ah C5 A

Ampere Ampere hours Rated current

C5 Ah

Rated capacity for 5 hours

g min N N.m Pa VDC

Gram Minute Newton Newton meter Pascal Volt direct current

°C % 

Degree Celsius Per cent Ohm

(2) U.S. Units ft in inHg lb lbf.in °F

Foot Inch Inchs of mercury Pound Pound force inch Degree Fahrenheit

(3) Multiplying Prefixes  m

da k M

Micro Milli Deca Kilo Mega

24-30-17


COMPONENT MAINTENANCE MANUAL 20VRED H. Measurement Conversion Table (1) From I.S. Measurement to U.S. Standard System 1 kPa 1 cm 1 cm² 1N 1g 1 kg 1 mm 1 N.m 1 N.m

0.1450 psi 0.3937 in 0.1550 in² 0.2248 lbf 0.0353 oz 2.2046 lb 0.0394 in 8.8507 lbf/in 0.7376 lbf/ft

(2) From U.S. Standard System to I.S. Measurement 1 psi 1 in 1 in 1 in² 1 lbf 1 oz 1 inHg 1 lb 1 gal (U.S.) 1 lbf/in 1 lbf/ft

6,8948 kPa 2,54 cm 25,4 mm 6,4516 cm² 4,4482 N 28,3495 g 3,3864 kPa 0,4536 kg 3,7854 l 0,1130 N.m 1,3558 N.m

I. Temperature Conversion Table (a) SI MEASUREMENT Degrees Celsius (°C) Celcius =

 Fa hre nheit – 0,555 5 32  

(b) U.S. STANDARD SYSTEM Degrees Fahrenheit (°F) F ah re nh ei t =

 Ce lc iu s  1,8  + 32

J. Abbreviations The abbreviations given below are used in this manual: AECMA ATA dia. fig. ipl max. mfr min.

European Association of Aerospace Industries Air Transport Association of America diameter figure illustrated parts list maximum manufacturer minimum

24-30-17


COMPONENT MAINTENANCE MANUAL 20VRED n° od p/n para. ref. s/a TBD V

number outside diameter part number paragraph refer to subassembly to be defined Voltage

K. Verifications (1) The functions (tasks) which are given in this manual were verified by simulation. This component maintenance manual is "shop verified" after all the functions (tasks) are actually done on the equipment. (2) We will revise this statement after all verifications are made. (3) The list of Page Blocks gives the shop verifications which are actually made. We will revise this statement after all verifications are made. L. Definition (1) This paragraph describes the warnings used in this manual. (2) Warnings call attention to use of materials, steps procedures, or limits, which must be followed precisely to avoid injury to persons. (3) Cautions call attention to steps procedures which must be followed to avoid damage to equipment. (4) Notes call attention to procedures which make the job easier. M. Disposal Ni-Cd batteries contain : - nickel, - cadmium, - potassium hydroxide. They must therefore be discarded or used again, in agreement with local legislation. For more information, contact your local SAFT supplier.

Recyclable Product Figu re INTRO-1/GRAPHIC 24-30-17-991-069-A01

24-30-17



DESCRIPTION AND OPERATION 1. Description A. General The alkaline battery has 20 nickel-cadmium VRED cells. The battery is connected to the aircraft systems. NOTE:The 28.5 VDC electri cal system charges the battery in the aircraft. The figure and item numbers are those of the ILLUSTRATED PART LIST. B. Characteristics (1) Technical data Technical data

Values

Type of cells

VRED

Number of cells

20

Nominal voltage

24 V

Rated capacity C 5 Ah (Ah) see Note below

4.5 Ah

End of life criteria in %

80%

NOTE: Rated capacity, noted C5 Ah or C5Ah, is measur ed at th e 5 h r ate (0.9 A). (2) Operational characteristics Operating temperature : 23 ± 5 °C (73 ± 9 °F) (3) Electrical characteristics List of standard values used to service the battery Item

Value

Use for

0.2 C5 A

0.9 A

Discharge

0.1 C5 A

0.45 A

Charge

C. Detailed description The battery has 20 VRED cells housed in a white plastic box. Circuit breakers, fuse and eventually diodes protects the battery. A polyswitch regulates the charge current in the aircraft.

24-30-17

Page 1 Feb 18/2015



24-30-17

BLANK


TESTING AND FAULT ISOLATION 1. Introduction A. General This pageblock gives the tests and inspections required to find the condition of the unit removed for unscheduled maintenance. The test procedure is given in the TESTING AND FAULT ISOLATION TABLE, which for each test refers to a specific procedure specifying all relevant parameters. The figure and item numbers are those of the ILLUSTRATED PARTS LIST. NOTE:Do the tests at ambient condi tions : - Ambient temperature: 23 ± 5 °C (73 ± 9 °F). - Pressu re: 85 to 106 kPa (25.1 to 31.1 InHg). - Relative humidity: < 85 %. TASK 24-30-17-700-801-A01 2. Testing A. Reason fo r t he j ob This chapter is use to indicate the right chapter to use according to the technician needs B. Job set-up information NOTE:You can use equivalent alternatives for the items in those lis ts. NOTE:Refer to SPECIAL TOOLS, FIXTURES, EQUIPMENT AND MATERIALS for full data of special tools in thi s list. (1) Tools, fixtures and equipment - Standard mechanic’s tools. - Safety gloves. - Protective goggles. - Safety shoes. - Eye wash. (2) Consumables Not applicable. C. Job set-up NOTE:You mus t always do regular maintenance. It is then necessary to obey these precautions t o make sure that you h ave correct o peration o f the battery: Carefully obey the instructions given in the aircraft documentation to make sure that the flow of air is good. Regularly make sure that the capacity of the battery is co rrect . Charge the battery in a battery shop. You must do m aintenance, specially to make sure of cor rect charging.

24-30-17

Page 1001 Feb 18/2015

COMPONENT MAINTENANCE MANUAL 20VRED D. Maintenance guideline 1

New battery never used

Charge the battery (refer to TASK 24-

Yes

30-17-820-001-A01 )

No Battery to put in storage

Refer to chapter STORAGE

Yes

(INCLUDING TRANSPORTATION)

No Battery with fault

Refer to chapter INSPECTION/CHECK

Yes

No General Overhaul

Refer to chapter INSPECTION/CHECK

TASK 24-30-17-820-001-A01 3. Charge A. Reason of th e job Self explanatory B. Job set-up information NOTE:You can use equivalent alternatives for the items in those lis ts. NOTE:Refer to SPECIAL TOOLS, FIXTURES, EQUIPMENT AND MATERIALS for full data of special tools in t his list. (1) Tools, fixtures and equipment Code

Reference

Qty

Description

T01

No special

1

Discharge bench (constant current 0-5 A)

T02

No special

1

Power supply 0-40 V, 0-2 A

T03

No special

1

Multimeter range 2 V-50 V accuracy 1%

(2) Consumables None C. Job set up Not applicable

24-30-17

Page 1002 Feb 18/2015

COMPONENT MAINTENANCE MANUAL 20VRED D. Procedure (1) Constant current charge (Battery fully discharged) NOTE: If the battery v oltage does not increase above 27 V after 6 hours o f ch arge, refer to the chapter TESTING AND FAULT ISOLATION. CAUTION: When you charge the battery more th an in the table above, you decrease the life of the cells. (a) To charge a fully discharged battery, do these procedure. Main charge Current and duration 0.45 A (0.1 C5 A)

time

Maximum voltage

mini 14 h maxi 16 h

If the voltage is over 35 V, the battery must be discarded

CAUTION: (b) Battery not fully discharged and discharge condition unknown Discharge at 4.5 A (1 C 5 A) down to 20 V (24-30-17-800-802-A01 ). Charge : refer to 24-30-17-820-001-A01 above constant current charge E. Close-up Not applicable. TASK 24-30-17-800-802-A01 4. Discharge A. Reason of th e job Self explanatory B. Job set-up information NOTE:You can use equivalent alternatives for the items in those lis ts. NOTE:Refer to SPECIAL TOOLS, FIXTURES, EQUIPMENT AND MATERIALS for full data of special tools in thi s list. (1) Tools, fixtures and equipment Code

Reference

Qty

Description

T01

No special

1


T02

No special

1


T03

No special

1


(2) Consumables None C. Job set up Not applicable

24-30-17

Page 1003 Feb 18/2015

COMPONENT MAINTENANCE MANUAL 20VRED D. Procedure SUBTASK 24-30-17-820-004-A01 (1) Discharge Rated capacity (C 5 Ah)

minimum duration depends on the battery model (value obtained for a fully charged battery, when discharged at 0.9 A, down to 20 V).

Other rates (C5 A)

Depending on temperature and time: up to 4.5 C 5 A.

24-30-17

Page 1004 Feb 18/2015


SCHEMATIC A ND WIRING DIAGRAMS TASK 24-30-17-871-804-A01 1. General This page block gives all electrical schematics of battery A. 804751 elec tr ic al s ch ematic

-

+

804751 electrical schematic Figu re 2001/GRAPHIC 24-30-17-991-055-A01

24-30-17

Page 2001 Feb 18/2015

COMPONENT MAINTENANCE MANUAL 20VRED B. 804747 electri cal schematic

B

F2A

D

B 7.5 A A polyswitch C 804747 electrical schematic Figu re 2002/GRAPHIC 24-30-17-991-055-A01

24-30-17

Page 2002 Feb 18/2015

COMPONENT MAINTENANCE MANUAL 20VRED C. 804748 electrical s chematic

B

F2A

D

B 15 A A polyswitch C 804748 electrical schematic Figu re 2003/GRAPHIC 24-30-17-991-055-A01

24-30-17

Page 2003 Feb 18/2015

COMPONENT MAINTENANCE MANUAL 20VRED D. 804749 electrical s chematic

B

F2A

D

B 7.5 A A polyswitch C B 10 A E 804749 electrical schematic Figu re 2004/GRAPHIC 24-30-17-991-055-A01

24-30-17

Page 2004 Feb 18/2015

COMPONENT MAINTENANCE MANUAL 20VRED E. 804745 electri cal schematic

B

F2A

D

B 2.5 A A polyswitch C B 15 A E 804745 electrical schematic Figu re 2005/GRAPHIC 24-30-17-991-055-A01

24-30-17

Page 2005 Feb 18/2015

COMPONENT MAINTENANCE MANUAL 20VRED F. 806653 electri cal schematic C D E F

F2A

M J

A B B 25 A

H G

polyswitch K L

806653 electrical schematic Figu re 2006/GRAPHIC 24-30-17-991-055-A01

24-30-17

Page 2006 Feb 18/2015


DISASSEMBLY TASK 24-30-17-800-802-A01 1. Introduction A. General WARNING:DO ALL STEPS ON FULLY DISCHARGED BATTERIES. NOTE:Refer to chapter TESTING AND FAULT ISOLATION to find the condition of the component or the possible cause of its malfunction. This will give the necessary level of di sassembly. NOTE:Battery di sassembly, except when done to change the battery pack, voids the warranty. NOTE:Corrosio n on i ntercell connectio ns is acceptable and does not affect battery p erformance. B. Safety The Safety rules are different from one country to another. Only local rules are applicable. C. Risks There are three types of risks. (1) Physical - Use protective shoes. (2) Electrical - Don’t keep on you rings, watches, chains, belt buckles. - Use insulated tools. (3) Chemical - Electrolyte is very corrosive and can cause dangerous damage to the skin: use gloves - Electrolyte is very dangerous for eyes, use protective goggles. D. Safety measure The electrolyte is normally contained within the cells. Never pierce, cut, open or dismantle the cells or the battery pack (040) The electrolyte compound is caustic and can cause dangerous burns. If it touches the skin, flush the touched part with water and make neutral the solution with acetic solution, vinegar or lemon juice, or with boric acid solution at 10% concentration. If the electrolyte touches the eyes, flush them with water for 15 minutes at minimum and immediately get a doctor. Electrolyte ingestion can cause damage to the throat and the respiratory tract. Do not try to vomit. Mix the solution with water or, if possible, with milk. Get a doctor immediately. Contact with nickel can cause chronic eczema. To breathe cadmium oxide can cause a dry throat, make you cough, cause headaches, vomiting, or pain in your chest. Persons having breathed cadmium oxide fumes must get fresh air or get oxygen or must have artificial respiration. Potash can cause eczema

24-30-17

Page 3001 Feb 18/2015

COMPONENT MAINTENANCE MANUAL 20VRED TASK .24-30-17-000-801-A01 2. Disassembly A. Reason fo r t he j ob Do this task only for changing the battery pack (040) if the results are unsatisfactory during the inspection/check (refer to 24-30-17-200-801-A01 ). B. Consumables None C. Job set up Not applicable D. Procedure SUBTASK 24-30-17-020-001 NOTE:This p rocedure is used onl y wh en the battery pack (040) has to be changed. (1) Disassembly of the batterry pack procedure WARNING:DO ALL STEPS ON FULLY DISCHARGED BATTERIES (24-30-17-800802-A01). (a) Unscrew the four screws (010) (b) Unscrew the 3 upper screws (050) (c) Remove the flanges (030) (d) Unsolder the wires from the connections without cutting the wire from the other components. E. Close up Not applicable

24-30-17

Page 3002 Feb 18/2015


CLEANING TASK 24-30-17-871-806-A01 1. Introduction A. General The figure and item numbers are those of the ILLUSTRATED PARTS LIST. TASK 24-30-17-100-801-A01 2. Cleaning of a uni t A. Reason fo r t he j ob Self explanatory B. Job set-up information NOTE:You can use equivalent alternatives for the items in those lis ts. NOTE:Refer t o SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMMABLES for full data of special tools in t his list. (1) Tools, fixtures and equipment - Safety gloves. - Protectives goggles. - Safety shoes. - Eye washing. (2) Consumable - Soap C. Job set up Not applicable D. Procedure WARNING:The electrolyte is dangerous. Be careful when handling electrolyte and avoid splashing. It is a st rong c austic agent and can cause severe burns . Always wear face and eye protectio n (preferably A tr ansparent face mask, rubber glo ves and long sleeved clothing). In case of contact wit h skin, flush i mmediately with m uch water. In case of contact with eyes, flush with water at least 15 minutes and, in all cases, get i mmediate medical attention . WARNING:The battery must be discharged (refer to 24-30-17-800-802-A01) before cleaning. SUBTASK 24-30-17-160-001-A01 (1) Light cleaning (a) Flanges (030) Clean with lightly soapy water, rub with a cloth and let dry. (b) All others components A dry cleaning with a non-conductive brush can be done on all the other components. E. Close up Not applicable

24-30-17

Page 4001 Feb 18/2015



24-30-17

BLANK


INSPECTION/CHECK TASK 24-30-17-871-805-A01 1. Introduction A. General You must do the checks which are necessary to use the SAFT batteries in flight and on the ground. These maintenance steps must be done in a battery shop between 23 °C ± 5 °C (73 ± 9 °F): TASK 24-30-17-200-801-A01 2. Maintenance steps in workshop A. Reason fo r t he job Self-explanatory B. Job set-up information NOTE:You can use equivalent alternatives for the items in those lis ts. NOTE:Refer t o SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMMABLES for full data of special tools in t his list. (1) Tools, fixtures and equipment Code

Reference

Qty

Description

T01

No special

1


T02

No special

1


T03

No special

1


- Standard mechanic’s tools. - Safety gloves. - Protective goggles. - Safety shoes. - Eye wash. - Protective apron. (2) Consumable s Not applicable C. Job set-up Do the check at ambient condit ions: - Ambient temperature: 23 ± 5 °C (73 ± 9 °F). - Pressu re: 85 to 106 kPa (25.1 to 31.3 InHg). - Relative humidity: < 85 %.

24-30-17

Page 5001 Feb 18/2015

COMPONENT MAINTENANCE MANUAL 20VRED D. Procedure SUBTASK 24-30-17-210-001-A01 E. General overhaul (minimum 1 per year) This overhaul includes electrical tests. Follow the different steps indicated below for the right battery. If the results are unsatisfactory, repeat the test. If the same result are obtained, the battery pack (040) must be changed. The battery pack (040) is a non-repairable part. (1) 804751 battery (a) Battery pack test NOTE: If the battery v oltage does not increase above 27 V after 6 hours o f ch arge, refer to the c hapter TESTING AND FAULT ISOLATION. Test

connection

Residual capacity

- and +

Discharge at 2.5 A down to 23 V

none

Capacity test

- and +

Charge the battery at 0.45 A during 16 h

Voltage must be less than 35 V. If not OK discard the battery.

Let the battery in place for 1 h

none

- and +


Discharging period must be 4 h or more.

- and +

Charge the battery at 28.5 V during 16 h

none

- and +

Discharge the battery at 5 A down to 20 V

Discharging period must be 25 min or more.

Measure the voltage of the half battery section after 10 ± 1 min at 5 A rate

The difference of voltage between the 2 halves of battery must be less than 0.8 V.


Voltage must be less than 35 V. If OK the battery is charged, if not OK discard the battery.

-

Charge at constant voltage

- and + and middle point Final charge

- and +

sequence

result

24-30-17

Page 5002 Feb 18/2015

COMPONENT MAINTENANCE MANUAL 20VRED (2) 804747 battery (a) Battery pack test B is the ground terminal NOTE: If the battery v oltage does not increase above 27 V after 6 hours o f ch arge, refer to the chapter TESTING AND FAULT ISOLATION. Test

connection

Residual capacity

A - B


none

Capacity test

B-C




none

A - B



B-C


none

A - B




The difference of voltage between the 2 halves of battery must be less than 0.8 V



-


DB and AD

Final charge

B-C

sequence

result

24-30-17

Page 5003 Feb 18/2015

COMPONENT MAINTENANCE MANUAL 20VRED (3) 804748 battery (a) Battery pack test B is the ground terminal. NOTE: If the battery v oltage does not increase above 27 V after 6 hours o f c harge, refer to the chapter TESTING AND FAULT ISOLATION.. Test

connection

Residual capacity

A - B


none

Capacity test

B-C




none

A - B



B-C


none

A - B







-


DB and AD

Final charge

B-C

sequence

result

24-30-17

Page 5004 Feb 18/2015

COMPONENT MAINTENANCE MANUAL 20VRED (4) 804749 battery (a) Battery pack test B is the ground terminal. NOTE: If the battery v oltage does not increase above 27 V after 6 hours o f ch arge, refer to the chapter TESTING AND FAULT ISOLATION. Test

connection

Residual capacity

A - B


none

Capacity test

B-C




none

A - B



B-C


none

B-E




The difference of voltage between the 2 halves of battery must be less than 0.8 V



-


DB and ED

Final charge

B-C

sequence

result

24-30-17

Page 5005 Feb 18/2015

COMPONENT MAINTENANCE MANUAL 20VRED (5) 804745 battery (a) Battery pack test B is the ground terminal NOTE: If the battery v oltage does not increase above 27 V after 6 hours o f c harge, refer to the chapter TESTING AND FAULT ISOLATION.. Test

connection

Residual capacity

A - B


none

Capacity test

B-C




none

A - B



B-C


none

B-E







-


DB and AD

Final charge

B-C

sequence

result

24-30-17

Page 5006 Feb 18/2015

COMPONENT MAINTENANCE MANUAL 20VRED (6) 806653 battery (a) Batte Battery ry pack pack test test B is the ground terminal NOTE NOTE:: If the battery v oltage does not increase above above 27 V after 6 hours o f ch arge, refer to the chapter TESTING AND FAULT ISOLATION.. Tes t Residual capacity Capacity test


Final charge

c o n n ec t i o n

s eq u en c e

r es u l t

CDEF CDEF - AB ABHG HG

Disc Discha harg rge e at at 2.5 2.5 A dow down n to to 23 V

none

CDEF - KL



-


none

CDEF CDEF - AB ABHG HG

Disc Discha harg rge e at at 0.9 0.9 A dow down n to to 20 V


CDEF - KL KL

Charg harge e the the batt batte ery at 28. 28.5 5V during 16 h

none

CDEF CDEF - ABH ABHG G

Disc Discha harg rge e the the batt batter ery y at at 5 A down to 20 V


CDEF - MJ and MJ - ABHG



CDEF - KL



24-30-17

Page 5007 Feb 18/2015



24-30-17

BLANK


REPAIR 1. General As indicated indicated in the CHECK chapter, chapter, defective parts for which which no repair repair instructions instructions are given given shall be rejected and replaced by new parts. The figure and item numbers used in this chapter correspond with those of the ILLUSTRATED PARTS LIST. 2. Equipment A. Special Spec ial to ol s When special tools are used in this chapter, they are identified by a code number listed in the chapter SPECIAL TOOLS, FIXTURES AND EQUIPMENT. B. Standa tandard rd tools Standard mechanic’s tools. C. Materia Materials ls Not applicable 3. Repairs The only authorized repair applicable applicable to the unit is: - Changing the battery pack (040).

24-30-17

Page 6001 Feb 18/2015


REPAIR N°1 TASK 24-30-17 24-30-17-900-801 -900-801 4. Changing th e battery pack (040) (040) A. General Gener al The battery pack pack (040) is a non reparable reparable unit. B. Detaile Detailed d procedure - Dissasemble the battery (refer to DISASSEMBLY Task. 24-30-17-020-001 ) - Place a new pack battery (040) - Place 20 mm of sleeve on the red wires and solder them on the positive connection - Place 20 mm of sleeve on the black wire and solder it on the negative connection - Place 20 mm of sleeve on the white wire and solder it on the middle connection - Assemble the upper flange with the screws (010) ans the nuts (020) - Place the 6 screws (050).

24-30-17

Page 6002 Feb 18/2015


ASSEMBLY TASK 24-30-17-871-810-A01 1. Introduction A. General You must assemble parts on a clean workbench in a clean, dry room. The parts must be protected from impact damage. For tightening parts refer to the torque table (Ref. TASK-24-30-17-400-802-A01 ). Make sure that the storage protection layer is removed from the new part before assembly. The figure and item numbers used are those of the ILLUSTRATED PARTS LIST. To do check points, refer to INSPECTION/CHECK . TASK 24-30-17-400-801-A01 2. Assembly procedure A. Reason fo r t he job Self-explanatory B. Job set-up information NOTE:You can use equivalent alternatives for the items in those lis ts. NOTE:Refer t o SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMMABLES for full data of special tools in t his list. (1) Tools, fixtures and equipment not applicable (2) Consumables Not applicable C. Job set-up Not applicable D. Procedure SUBTASK 24-30-17-420-001-A01 (1) Installation of the upper flange Assemble the upper flange withe the screw (010) ans the nuts (020) SUBTASK 24-30-17-970-001-A01 (2) Write the necessary information on: (a) the log book. E. Close up Not applicable

24-30-17

Page 7001 Feb 18/2015



24-30-17

BLANK


FITS AND CLEARANCES TASK 24-30-17-400-802-A01 1. Torque table SUBTASK 24-30-17-820-005-A01 A. Tor que tab le List of all applicable torque values needed to assemble and do servicing of the battery: NOTE:The values here are " lube tor que" values. The threads shoul d be li ghtly greased before to installation and applying torq ue. IPL FIG ITEM N°

TORQUE VAL UE NAME

010 050

N.m

lbf.in

Screw

2 ± 0.2

17.7 ± 1.8

screw

1 ± 0.1

8.85 ± 0.9

24-30-17

Page 8001 Feb 18/2015



24-30-17

BLANK


SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMMABLES TASK 24-30-17-940-801-A01 1. Special tools, fixtures and equipment A. Special to ol s t abl e NOTE:Equivalent alternatives can be used for list items. Tool code

Part number

Description

Supplier code or name and address

Page block where necessary

Qty

T01

No special


Local purchase

1000 5000

1

T02

No special


Local purchase

1000 5000

1

T03

No special


Local purchase

1000 5000

1

TASK 24-30-17-13-941-801-A01 2. Consumables material A. Consumab le mater ial s t able Material number M01

Description Soap

Supplier code or name and address Local purchase

24-30-17

Page block where necessary 4000

Page 9001 Feb 18/2015



24-30-17

BLANK


ILLUSTRATED PARTS LIST

24-30-17

Page 10001 Feb 18/2015



24-30-17

BLANK


INTRODUCTION TASK 24-30-17-871-802-A01 1. Introduction A. General The Illustrated Parts List (IPL) contains a list and illustrations of the assemblies and detailed parts of the unit in disassembly sequence. It includes the following sections : - Introduction (INTRO), - Numerical Index (NI), - Detailed Parts List (DPL). B. How to Use the illustrated Parts List (1) To find the illustration for a part if the part number is known, refer to the Numerical Index and look for the part number and the corresponding figure and item number. Refer to the Detailed Parts List and look for the first figure and item number found in the Numerical Index for that part. If this figure shows the part in a section or system of the equipment other than the one necessary, refer to the other figure numbers listed in the Numerical Index. (2) To determine the part number of a given part, refer to the illustration showing the assembly including this part. Note the item number of the illustrated part and refer to the Detailed Parts List which indicates its part number and identification. C. Numerical Index (NI) (1) In this index, part numbers are classified in the following order: (a) The classification is made from left to right, each character (letter, number, hyphen) being considered separately. (b) The sequence in the first left row is : 1 an alpha letter from A to Z (except for " O " and " I " to be considered as zero and one) 2 numeral from 0 to 9. (c) For the subsequent rows, the sequence is: 1 a dash, 2 an alpha letter A to Z (but not the "O" and the "I", because it is possible to read these letters as a zero and a one), 3 a numeral 0 to 9. (d) The part number column contains all part numbers included in the Detailed Parts List. The part numbers that have been deleted or superseded within the Detailed Part List are listed in the Numerical Index and identified as deleted or superseded. D. Detailed Parts List (DPL) (1) Figure and Item Number (a) Each assembly, sub-assembly and part holding a part number and included in the parts list is given as an item number. (b) The figure number linked to the item number is shown on the first line at the top of each

24-30-17

Page 10003 Feb 18/2015

COMPONENT MAINTENANCE MANUAL 20VRED page. (c) Assemblies, sub-assemblies numbered parts included in the list but not illustrated are identified by a hyphen (-) preceding the item number. (d) An index letter shown before the item number refers to the figure showing the modified portion of the applicable part. (2) Manufacturer's Part Number A manufacturer's part number is given to each assembly and detail part, whether illustrated or not. (3) Nomemclature (a) The nomenclature is given with an indenture, to show how the parts and the assemblies and related to their next higher assemblies. These are the details: : 1234567 Assembly . Detailed parts for assembly, . Sub-assembly . Attaching parts and/or storage parts for sub-assembly, *** . . Detailed parts for sub-assembly . . Sub-sub-assembly, . . Attaching parts and/or storage parts for sub-sub-assembly, *** . . . Detailed parts for sub-sub-assembly. (b) The attaching parts are shown directly after the assembly of the part thereof. They are listed under the same indent number as the item they are attached to, and are identified by the words "Attaching Parts" and are followed by three asterisks. (c) The manufacturer's code or the abbreviation NP (not procurable) are placed at the extreme right- hand side of the first line of the parts list column. (4) Effectivity code 1 An alphanumerical index indicates the effectivity of sub-assemblies and detailed parts lists in relation to the next higher assembly (ies) or sub-assembly (ies). 2 When the effectivity is fully applicable, the usage code column remains blank. 3 The use code for assemblies and detailed parts refers to the figure/item number of the next higher assembly (ies) or sub-assembly (ies). Example : Effectivity 1A, 1B, 1C is written 1ABC. (5) Units per Assembly (a) The units per assembly column showns the quantity of units required for one next higher assembly. (b) In some cases, the information is replaced by the abbreviation RF (for reference) or AR

24-30-17

Page 10004 Feb 18/2015

COMPONENT MAINTENANCE MANUAL 20VRED (as required). (6) Abbreviation used ALT FROM PNR XXX AMDT AR DELETED DET DPL EDI IPL LH MFR MODIFIED FROM NHA NP OLD PNR OPT SEE TABLE ORDER OVRLGTH PNR OVERSIZE PNR POST SB PRE SB R RF RH SEE CMM SEE FIG FOR DET SEE FIG FOR NHA SEL FROM SUPSD BY SUPSDS UNDERSIZE VL

Part that is functionally and physically interchangeable with original part after reworking. Amendment As required Deleted part Detail Detailed Parts List Equipment Designator Index Illustrated Parts List Left hand Manufacturer or Optional Manufacturer in the IPL A part got after a different part is modified Next higher assembly Not procurable Optional part number. Optional part number that is fully interchangeable with the part in the part number column. Refer to the optional table A part number with more than fifteen chararacters A part with a size which is larger than its nominal dimension Part number. After a modification given up by a Service Bulletin. Before modification given up by a Service Bulletin. Revised For reference. Right hand. Refer to the Component Maintenance Manual. Refer to figure for details. Refer to figure for next higher assembly. Selected from. A part that you must select from a collection of parts, as necessary Superseded by XXX. Supersedes XXX. A part with a size wich is smaller than its nominal voltage Vendors List.

E. Updating (1) General (a) When an item is revised, added or deleted, the letter " R " is shown in the right-hand margin (the date of issue changes). (2) Added items (a) The basic sequence of the items given from 10 to 10 makes it possible to add new items between the old ones in the appropriate order of the breakdown. With the addition of

24-30-17

Page 10005 Feb 18/2015

COMPONENT MAINTENANCE MANUAL 20VRED more than nine new items, a new number is to be added at the end of the IPL. (3) Deleted items (a) Should a part number definitively deleted, the information given in the parts list zone is deleted. The old part number always remains in the numerical index. (4) New Figure Number Added (a) When new illustrations are necessary the alternative figures are inserted. They refer to the same nomenclature. The alternative figure is given with the basic figure number and letter. This letter precedes the item number in the parts list.

24-30-17

Page 10006 Feb 18/2015


VENDOR LIST Code

Name

Address

F6177

Saft

12 rue Sadi Carnot 93170 Bagnolet France Phone: +33 (0) 1 49 93 19 18 Fax: +33 (0) 1 49 93 19 56

V09052

Saft America Inc.

711, Industrial Blvd Valdosta Georgia, 31601 USA Phone: +1 (229) 247 2331 Fax: +1 (229) 247 8486

24-30-17

Page 10007 Feb 18/2015



24-30-17

BLANK


AL PHA NUMERICAL INDEX PART NUMBER 804750

AIRLINE STOCK NUMBER

FIG NUMBER

INDEX NUMBER

040

TOTAL REQUIRED 1

- Item not illustrated.

24-30-17

Page 10009 Feb 18/2015



24-30-17

BLANK


DETAILED PARTS LIST

24-30-17

Page 10011 Feb 18/2015


010

030

040

030

020

804751 BATTERY Figu re 10001/GRAPHIC 24-30-17-991-020

24-30-17

Page 10012 Feb 18/2015


FIG. ITEM 01 - 001 010 020 030 040

PART NUMBER 804751 NP NP NP 804750


NOMENCLATURE 1234567 Battery, 20VRED Screw CHC M5x55, stainless steel Nut M5, stainless steel Flange Battery pack

EFF. CODE

UNITS PER ASSY RF 4 4 2 1


24-30-17

Page 10013 Feb 18/2015


010

030

040

030

060

020

050 804747 BATTERY Figu re 10002/GRAPHIC 24-30-17-991-020

24-30-17

Page 10014 Feb 18/2015


FIG. ITEM 02 - 001 010 020 030 040 050 060

PART NUMBER 804747 NP NP NP 804750 NP NP


NOMENCLATURE 1234567 Battery, 20VRED Screw CHC M5x55, stainless steel Nut M5, stainless steel Flange Battery pack Screw M3x16, stainless steel Fuse 5x20 mm, 2 A, fast blow

EFF. CODE

UNITS PER ASSY RF 4 4 2 1 6 1


24-30-17

Page 10015 Feb 18/2015


010

030

040

030

060

020

050 804748 BATTERY Figu re 10003/GRAPHIC 24-30-17-991-020

24-30-17

Page 10016 Feb 18/2015


FIG. ITEM 03 - 001 010 020 030 040 050 060




EFF. CODE



24-30-17

Page 10017 Feb 18/2015


010

030

040

030 060

020

050


24-30-17

Page 10018 Feb 18/2015


FIG. ITEM 04 - 001 010 020 030 040 050 060




EFF. CODE



24-30-17

Page 10019 Feb 18/2015


010

030

040

030 060

020

050


24-30-17

Page 10020 Feb 18/2015


FIG. ITEM 05 - 001 010 020 030 040 050 060




EFF. CODE



24-30-17

Page 10021 Feb 18/2015


010

030

040 060

030 050 020


24-30-17

Page 10022 Feb 18/2015


FIG. ITEM 05 - 001 010 020 030 040 050 060




EFF. CODE



24-30-17

Page 10023 Feb 18/2015



24-30-17

BLANK


STORAGE (INCLUDING TRANSPORTATION) TASK 24-30-17-871-809-A01 1. Introduction A. General NOTE:do not store a di scharged battery. Original manufacturer packaging protects the equipment against any external damage during storage. If this original packaging is not available, place the battery in a sealed plastic bag with a desiccant in a cardboard box. The figure and item numbers used in this chapter correspond with those of the ILLUSTRATED PARTS LIST. B. Storage room Keep the equipment in a dry and clean room isolated from detrimental agents such as dirt, dust, vibrations or corrosive atmosphere. C. Temperature conditions Saft recommends to store the battery within the temperature range +5°C to +25°C (+41°F to +77°F) in a 65% ± 10% relative humidity atmosphere. TASK 24-30-17-871-809-A01. 2. Stand-by storage procedure A. Reason fo r t he job The battery is charged after being serviced then stored fully charged in a dedicated room. The battery can be installed in the aircraft without further check B. Job set-up information (1) Tools, fixtures and equipment None (2) Consumable s None C. Job set up Do the check at ambient condit ions: - Ambient temperature: 23 ± 5 °C (73 ± 9 °F). - Pressu re: 85 to 106 kPa (25.1 to 31.3 InHg). - Relative humidity: < 85 %. D. Procedure SUBTASK 24-30-17-550-001-A01 (1) Preparation of the battery before storage (a) The battery must be fully charged for storage. If the battery is fully discharged, charge the battery (refer to task 24-30-17-820-004-A01 ) before storage. If the battery is in an unknown state of charge then: 1 do a residual discharge at 4.5 A rate (1C 5 A) down to 20 V . 2 charge the battery (refer to task 24-30-17-820-004-A01 )

24-30-17

Page 15001 Feb 18/2015

COMPONENT MAINTENANCE MANUAL 20VRED (b) Place the equipment in its usual upright position in its storage packaging. SUBTASK 24-30-17-530-001-A01 (2) Place the equipment within its storage packaging in the storage room (3) The battery can be stored for a limited period of time so that it will retain 80% of its rated capacity. Since the charge retention depends on the storage temperature, the storage period must not exceed the values of the following table. Storage temperature

<20°C

20°C to 25 °C

25°C to 30°C

30°C to 35°C

35°C to 40°C

40

30

20

10

7

Storage period (days)

(4) At the end of the storage period, charge the battery at 0.45 A during 5 hours. (5) After 3 consecutive cycles of storage period/topping charge and prior to a new stand-by storage period do (a) A residual discharge at 4.5 A rate (1C 5 A) down to 20 V (b) A charge of the battery (refer to task 24-30-17-820-004-A01 ) (6) After 9 consecutive cycles or 1 year of stand-by storage, whichever comes first, do a general overhaul section prior to a new stand-by storage period E. End of the stand-by storage CAUTION:if the procedure descri bed in t he above paragraph is n ot f ollowed, there is a risk of placing a battery onb oard the aircraft that does not m eet the emergency requirements The active stand-by storage can be interrupted at any time in order to immediately install the battery onboard an aircraft without the need for additional tasks TASK 24-30-17-550-003-A01 3. Long term storage procedure A. Reason fo r t he j ob The battery is charged after being serviced then stored fully charged in a dedicated room for long periods of time between maintenance tasks B. Job set-up information (1) Tools, fixture and equipment None (2) Consumables None C. Joob set up Do the check at ambient condi tions : - Ambient temperature: 23 ± 5 °C (73 ± 9 °F). - Pressure: 85 to 106 kPa (25.1 to 31.3 InHg). - Relative humidity: < 85 %.

24-30-17

Page 15002 Feb 18/2015

COMPONENT MAINTENANCE MANUAL 20VRED D. Procedure (1) Preparation of the battery before storage The battery must go in storage fully charged. If the battery is fully discharged, then charge the battery (refer to task 24-30-17-820-004-A01 ) before storage. If the battery is in an unknown state of charge, discharge at 4.5 A rate (1C 5 A) down to 20 V then charge the battery (refer to task 24-30-17-820-004-A01 ) before storage (2) Place the equipment in its usual upright position in its storage packaging in the storage room (3) The maximum duration of a storage period is driven by the battery voltage evolution: do periodical battery open circuit voltage checks in order to do not let the voltage fall below 18 V as defined in the table below. Battery performances can be seriously decreased in case of long storage at low voltage. Storage temperature Storage duration for the first voltage check Interval between subsequent checks

less than 25 °C

25 to 30 °C

30 to 35 °C

35 to 40 °C

12 months

8 months

4 months

2 months

1 month

1 month

2 weeks

1 week

(4) At the end of the storage period do the general overhaul section prior to a new long term storage period NOTE: It may be necessary to repeat up to 5 times the electric al treatment of the overhaul, in order to wake-up a battery after long t erm storage. A battery that does not m eet the capacity c riteria after 5 overhaul cy cles shall be rejected. E. End of the long term storage (1) The long term storage can be interrupted at any time in order to prepare the battery for installation onboard an aircraft. (2) If the last overhaul cycle has been done within the last 4 months, do the following tasks for battery preparation before installation in the aircraft (a) A residual discharge at 4.5 A rate (1C5 A) down to 20 V. (b) A charge the battery (refer to task 24-30-17-820-004-A01 ). (3) If the last overhaul cycle has been done more than 4 months ago, do a new overhaul before installing the battery in the aircraft. TASK 24-30-17-500-801-A01 4. Transportation procedure A. General (1) The battery should then be packed in its original container. If the original container is not available, the international and/or local packaging regulations applicable to the mode of transport and destination must be followed.

24-30-17

Page 15003 Feb 18/2015

SAFT Battery Maintenance Manual

Recommend Documents