(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 ILLUSTRATED PARTS LIST AIRCRAFT BATTERY 20VR4D series 122849 135687 783543 785229 800864 803551 Initial issue: Sep 05/2006 24-30-16 Page 1 Revision n°. 2 Jun 02/2008 COMPONENT MAINTENANCE MANUAL 20VR4D PAGE INTENTIONALLY LEFT BLANK 24-30-16 BLANK COMPONENT MAINTENANCE MANUAL 20VR4D RECORD OF REVISION Inserted Issue date Date By 1 Sep 05/ 2006 Sep 05/ 2006 Saft 2 Apr 15/ 2008 Apr 15/ 2008 Saft Rev. n° Rev. n° Issue date 24-30-16 Inserted Date By ROR Page 1 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D PAGE INTENTIONALLY LEFT BLANK 24-30-16 BLANK COMPONENT MAINTENANCE MANUAL 20VR4D RECORD OF TEMPORARY REVISION Temp rev. n° Issue date Inserted Date Removed By Date 24-30-16 By Page n° RTR Page 1 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D PAGE INTENTIONALLY LEFT BLANK 24-30-16 BLANK COMPONENT MAINTENANCE MANUAL 20VR4D SERVICE BULLETIN LIST Service bulletin Number Rev. Incorporation into CMM Date Title Rev. 24-30-16 SBL Page 1 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D PAGE INTENTIONALLY LEFT BLANK 24-30-16 BLANK COMPONENT MAINTENANCE MANUAL 20VR4D LIST OF EFFECTIVE PAGES TITLE PAGE 1 2 May 14/2008 Blank RECORD OF REVISIONS 1 2 May 14/2008 Blank TESTING AND FAULT 1001 ISOLATION 1002 1003 1004 May 14/2008 May 14/2008 May 14/2008 May 14/2008 SCHEMATIC AND WIRING DIAGRAMS 2001 2002 2003 2004 2005 2006 May 14/2008 May 14/2008 May 14/2008 May 14/2008 May 14/2008 May 14/2008 RECORD OF TEMPORARY REVISIONS 1 2 May 14/2008 Blank SERVICE BULLETIN LIST 1 2 May 14/2008 Blank LIST OF EFFECTIVE PAGES 1 2 May 14/2008 May 14/2008 DISASSEMBLY 3001 3002 May 14/2008 May 14/2008 TABLE OF CONTENT 1 2 3 4 May 14/2008 May 14/2008 May 14/2008 May 14/2008 CLEANING 4001 4002 May 14/2008 Blank LIST OF ILLUSTRATIONS 1 2 May 14/2008 May 14/2008 INTRODUCTION 1 2 3 4 5 6 7 8 May 14/2008 May 14/2008 May 14/2008 May 14/2008 May 14/2008 May 14/2008 May 14/2008 May 14/2008 INSPECTION/CHECK 5001 5002 5003 5004 5005 5006 5007 5008 May 14/2008 May 14/2008 May 14/2008 May 14/2008 May 14/2008 May 14/2008 May 14/2008 Blank DESCRIPTION AND OPERATION 1 2 May 14/2008 Blank 24-30-16 LEP Page 1 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D LIST OF EFFECTIVE PAGES REPAIR 6001 6002 May 14/2008 May 14/2008 ASSEMBLY 7001 7002 May 14/2008 Blank FITS AND CLEARANCES 8001 8002 May 14/2008 Blank SPECIAL TOOLS, 9001 FIXTURES, 9002 EQUIPMENT AND CONSUMABLES May 14/2008 Blank ILLUSTRATED PARTS LIST 10001 10002 May 14/2008 Blank INTRO IPL 10003 10004 10005 10006 10007 10008 May 14/2008 May 14/2008 May 14/2008 May 14/2008 May 14/2008 Blank ALPHA NUMERICAL INDEX 10009 10010 May 14/2008 Blank DETAILED PARTS LIST 10011 10012 10013 10014 10015 10017 10018 10019 10020 10021 10022 10023 10024 May 14/2008 May 14/2008 May 14/2008 May 14/2008 May 14/2008 May 14/2008 May 14/2008 May 14/2008 May 14/2008 May 14/2008 May 14/2008 May 14/2008 Blank STORAGE (INCLU15001 DING TRANSPORTA- 15002 TION) 15003 15004 May 14/2008 May 14/2008 May 14/2008 Blank 24-30-16 LEP Page 2 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D TABLE OF CONTENT RECORD OF REVISION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 RECORD OF TEMPORARY REVISION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 SERVICE BULLETIN LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 B. How to Use the Manual - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 C. Associated Publications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 D. Revision and updating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 E. CMM Page Blocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 F. Measurements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 G. Units of Measure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 H. Measurement Conversion Table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 I. Temperature Conversion Table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 J. Abbreviations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 K. Verifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 L. Definition - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 M. Disposal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 DESCRIPTION AND OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 1. Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 B. Characteristics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 C. Detailed description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 TESTING AND FAULT ISOLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2. Testing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. Reason for the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Job set-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. Maintenance guideline - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3. Charge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. Reason of the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Job set up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E. Close-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4. Discharge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. Reason of the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Job set up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1001 1001 1001 1001 1001 1001 1001 1002 1002 1002 1002 1002 1003 1003 1003 1003 1003 1003 1004 SCHEMATIC AND WIRING DIAGRAMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2001 24-30-16 TOC Page 1 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D TABLE OF CONTENT 1. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. 122849 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. 135687 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. 783543 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. 785229 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E. 800864 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - F. 803551 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2001 2001 2002 2003 2004 2005 2006 DISASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Risks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. Safety measure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2. Disassembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. Reason for the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Consumables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Job set up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E. Close up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001 3001 3001 3001 3001 3001 3001 3001 3001 3002 3002 3002 CLEANING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2. Cleaning of a unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. Reason for the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Job set up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E. Close up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001 4001 4001 4001 4001 4001 4001 4001 4001 INSPECTION/CHECK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2. Maintenance steps in workshop - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. Reason for the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Job set-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E. General overhaul (minimum 1 per year) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001 5001 5001 5001 5001 5001 5001 5002 5002 REPAIR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2. Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. Special tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Standard tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3. Repairs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6001 6001 6001 6001 6001 6001 6001 24-30-16 TOC Page 2 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D TABLE OF CONTENT REPAIR N°1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4. Changing the battery pack (040) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Detailed procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6002 6002 6002 6002 ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2. Assembly procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. Reason for the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Job set-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E. Close up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001 7001 7001 7001 7001 7001 7001 7001 7001 FITS AND CLEARANCES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8001 1. Torque table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8001 A. Torque table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8001 SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMMABLES - - - - - - - - - - - - - - - 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 ALPHA NUMERICAL INDEX - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10009 DETAILED PARTS LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10011 STORAGE (INCLUDING TRANSPORTATION) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Storage room - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Temperature conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2. Storage procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. Reason for the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Job set up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24-30-16 15001 15001 15001 15001 15001 15001 15001 15001 15001 15001 TOC Page 3 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D E. Close up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15003 3. Transportation procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15003 A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15003 24-30-16 Page 4 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D LIST OF ILLUSTRATIONS INTRO-1 2001 2002 2003 2004 2005 2006 10001 10002 10003 10004 10005 10006 15001 Recyclable Product - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 122849 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2001 135687 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2002 783543 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2003 785229 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2004 800864 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2005 803551 electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2006 122849 battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10012 135687 battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10014 783543 battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10016 785229 battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10018 800864 battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10020 803551 battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10022 Short term storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15002 24-30-16 LOI Page 1 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D PAGE INTENTIONALLY LEFT BLANK 24-30-16 BLANK COMPONENT MAINTENANCE MANUAL 20VR4D INTRODUCTION TASK 24-30-16-871-801-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. 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. 24-30-16 INTRO Page 1 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D 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 24-30-16 INTRO Page 2 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D must set. It also gives all the parameters for which you must do a check. The block diagram (refer to task 24-30-16-700-801-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: Always discard all the seals and gaskets during disassembly. 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. 24-30-16 INTRO Page 3 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D (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. 24-30-16 INTRO Page 4 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D (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. 24-30-16 INTRO Page 5 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D G. Units of Measure (1) I.S. Units A Ah C5A Ampere Ampere hours Rated current C5Ah Rated capacity for 5 hours g min N N.m Pa VDC Gram Minute Newton Newton meter Pascal Volt direct current °C % Ω 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 μ m da k M Micro Milli Deca Kilo Mega 24-30-16 INTRO Page 6 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D 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/min 0,1130 N.m 1,3558 N.m I. Temperature Conversion Table (a) SI MEASUREMENT Degrees Celsius (°C) Celcius = ( Fahrenheit – 32 ) × 0.555 5 (b) U.S. STANDARD SYSTEM Degrees Fahrenheit (°F) Fahrenheit = ( Celcius × 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 24-30-16 INTRO Page 7 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D 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 Figure INTRO-1/GRAPHIC 24-30-16-991-069-A01 24-30-16 INTRO Page 8 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D DESCRIPTION AND OPERATION 1. Description A. General The alkaline battery has 20 nickel-cadmium VR4D cells. The battery is connected to the aircraft systems. NOTE:The 28.5 VDC electrical 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 VR4D Number of cells 20 Nominal voltage 24 V Rated capacity C5Ah (Ah) see Note below 4 Ah End of life criteria in % 80% NOTE: Rated capacity, noted C5Ah or C5Ah, is measured at the 5 h rate (0.8 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 C5A 0.8 A Discharge 0.1 C5A 0.4 A Charge C. Detailed description The battery has 20 VR4D cells housed in a red plastic box. Circuit breakers, fuse and eventually diodes protects the battery. A polyswitch regulates the charge current in the aircraft. 24-30-16 Page 1 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D PAGE INTENTIONALLY LEFT BLANK 24-30-16 BLANK COMPONENT MAINTENANCE MANUAL 20VR4D 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. Do the tests at ambient conditions: - Ambient temperature: 23 ± 5 °C (73 ± 9 °F). - Pressure: 85 to 106 kPa (25.1 to 31.1 InHg). - Relative humidity: < 85 %. TASK 24-30-16-700-801-A01 2. Testing A. Reason for the job 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 lists. NOTE:Refer to SPECIAL TOOLS, FIXTURES, EQUIPMENT AND MATERIALS for full data of special tools in this 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 must always do regular maintenance. It is then necessary to obey these precautions to make sure that you have correct operation of 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 correct . Charge the battery in a battery shop. You must do maintenance, specially to make sure of correct charging. 24-30-16 Page 1001 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D D. Maintenance guideline 1 New battery never used Charge the battery (refer to TASK 24- Yes 30-16-820-001-A01) No Battery to put in storage Yes Refer to chapter STORAGE (INCLUDING TRANSPORTATION) Yes Refer to chapter INSPECTION/CHECK No Battery with fault No General Overhaul Refer to chapter INSPECTION/CHECK TASK 24-30-16-820-001-A01 3. Charge A. Reason of the job Self explanatory B. Job set-up information NOTE:You can use equivalent alternatives for the items in those lists. NOTE:Refer to SPECIAL TOOLS, FIXTURES, EQUIPMENT AND MATERIALS for full data of special tools in this 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 24-30-16 Page 1002 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D D. Procedure (1) Constant current charge (Battery fully discharged) (a) To charge a fully discharged battery, do these procedure.. Main charge Current and duration 0.4 A (0.1 C5A) time mini 14 h maxi 16 h Maximum voltage 31 V NOTE: If the battery voltage does not increase sufficiently during the maximum charge time, refer to the chapter TESTING AND FAULT ISOLATION. CAUTION: When you charge the battery more than in the table above, you decrease the life of the cells. (b) Battery not fully discharged and discharge condition unknown Discharge at 4 A (1 C5A) down to 20 V (24-30-16-800-802-A01). Charge : refer to 24-30-16-820-001-A01 above constant current charge E. Close-up Not applicable. TASK 24-30-16-800-802-A01 4. Discharge A. Reason of the job Self explanatory B. Job set-up information NOTE:You can use equivalent alternatives for the items in those lists. NOTE:Refer to SPECIAL TOOLS, FIXTURES, EQUIPMENT AND MATERIALS for full data of special tools in this 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 24-30-16 Page 1003 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D D. Procedure SUBTASK 24-30-16-820+004-A01 (1) Discharge Rated capacity (C5Ah) 3 h minimum (value obtained for a fully charged battery, when discharged at 0.8 A, down to 20 V). Other rates (C5A) Depending on temperature and time: up to 4 C5A. 24-30-16 Page 1004 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D SCHEMATIC AND WIRING DIAGRAMS TASK 24-30-16-871-804-A01 1. General This page block gives all electrical schematics of battery A. 122849 electrical schematic - + 122849 electrical schematic Figure 2001/GRAPHIC 24-30-16-991-055-A01 24-30-16 Page 2001 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D B. 135687 electrical schematic B F2A D B 7.5 A A polyswitch C 135687 electrical schematic Figure 2002/GRAPHIC 24-30-16-991-055-A01 24-30-16 Page 2002 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D C. 783543 electrical schematic B F2A D B 15 A A polyswitch C 783543 electrical schematic Figure 2003/GRAPHIC 24-30-16-991-055-A01 24-30-16 Page 2003 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D D. 785229 electrical schematic B F2A D B 7.5 A A polyswitch C B 10 A E 785229 electrical schematic Figure 2004/GRAPHIC 24-30-16-991-055-A01 24-30-16 Page 2004 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D E. 800864 electrical schematic B F2A D B 2.5 A A polyswitch C B 15 A E 800864 electrical schematic Figure 2005/GRAPHIC 24-30-16-991-055-A01 24-30-16 Page 2005 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D F. 803551 electrical schematic B R5K D F B3A D1 polyswitch D2 A C E 803551 electrical schematic Figure 2006/GRAPHIC 24-30-16-991-055-A01 24-30-16 Page 2006 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D DISASSEMBLY TASK 24-30-16-800-802-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 disassembly. 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 - Take off 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 TASK .24-30-16-000-801-A01 2. Disassembly A. Reason for the job Do this task only for changing the battery pack (040) if the results are unsatisfactory during the inspection/check (refer to 24-30-16-200-801-A01). B. Consumables None 24-30-16 Page 3001 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D C. Job set up Not applicable D. Procedure SUBTASK 24-30-16-020-001 NOTE:This procedure is used only when the battery pack (040) has to be changed. (1) Disassembly of the batterry pack procedure WARNING:DO ALL STEPS ON FULLY DISCHARGED BATTERIES (24-30-16-800-802A01). (a) Unscrew the four screws (010) (b) Unscrew the 3 upper screws (050) (c) Remove the sleeves (030) (d) Unsolder the wires from the connections without cutting the wire from the other components. E. Close up Not applicable 24-30-16 Page 3002 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D CLEANING TASK 24-30-16-871-806-A01 1. Introduction A. General The figure and item numbers are those of the ILLUSTRATED PARTS LIST. TASK 24-30-16-100-801-A01 2. Cleaning of a unit A. Reason for the job Self explanatory B. Job set-up information NOTE:You can use equivalent alternatives for the items in those lists. NOTE:Refer to SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMMABLES for full data of special tools in this 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 strong caustic agent and can cause severe burns. Always wear face and eye protection (preferably A transparent face mask, rubber gloves and long sleeved clothing). In case of contact with skin, flush immediately with much water. In case of contact with eyes, flush with water at least 15 minutes and, in all cases, get immediate medical attention. WARNING:The battery must be discharged (refer to 24-30-16-800-802-A01) before cleaning. SUBTASK 24-30-16-160-001-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 24-30-16 Page 4001 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D PAGE INTENTIONALLY LEFT BLANK 24-30-16 BLANK COMPONENT MAINTENANCE MANUAL 20VR4D INSPECTION/CHECK TASK 24-30-16-871-805-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 24-30-16-200-801-A01 2. Maintenance steps in workshop A. Reason for the job Self-explanatory B. Job set-up information NOTE:You can use equivalent alternatives for the items in those lists. NOTE:Refer to SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMMABLES for full data of special tools in this 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% - Standard mechanic’s tools. - Safety gloves. - Protective goggles. - Safety shoes. - Eye wash. - Protective apron. (2) Consumables Not applicable C. Job set-up Do the check at ambient conditions: - Ambient temperature: 23 ± 5 °C (73 ± 9 °F). - Pressure: 85 to 106 kPa (25.1 to 31.3 InHg). - Relative humidity: < 85 %. 24-30-16 Page 5001 Jun 02/2008 COMPONENT MAINTENANCE MANUAL 20VR4D D. Procedure SUBTASK 24-30-16-210-001-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) 122849 battery (a) Battery pack test Test connection Residual capacity - and + Discharge at 2.5 A down to 23 V none Capacity test - and + Charge the battery at 0.4 A during 16 h Voltage must be less or equal to 31 V at the end of charge. - Let the battery in place for 4 h none - and + and middle point Measure the voltage of the half battery section The difference of voltage between the 2 halves of battery must be less than 1 V. - and + Discharge at 0.8 A down to 20 V Discharging period must be 3 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. - and + Charge the battery at 0.4 A during 16 h The battery is charged. Charge at constant voltage Final charge sequence result (2) 135687 battery (a) Battery pack test B is the ground terminal Test connection Residual capacity A-B sequence result Discharge at 2.5 A down to 23 V none 24-30-16 Page 5002 Jun 02/2008 COMPONENT MAINTENANCE MANUAL 20VR4D Test connection sequence result B-C Charge the battery at 0.4 A during 16 h Voltage must be less than to 31 V at the end of charge - Let the battery in place for 4 h none DB and AD Measure the voltage of the half battery section The difference of voltage between the 2 halves of battery must be less than 1 V A-B Discharge at 0.8 A down to 20 V Discharging period must be 3 h or more. B-C Charge the battery at 28.5 V during 16 h none A-B Discharge the battery at 5 A down to 20 V Discharging period must be 25 min or more. B-C Charge the battery at 0.4 A during 16 h The battery is charged. Capacity test Charge at constant voltage Final charge (b) Wiring test Follow this test to verify the wiring. The test must be done with a fully charged battery. If a test fails, discard the battery. Test connection result analyses 1 B-A > 23 V 0 V: verify that the circuit breaker is pushed. Verify that the wires are soldered on the battery pack and that no wire are cut. A few volts: the battery is discharged 2 B-D About half the voltage of the battery 0 V: verify the fuse F, verify that the wire is not cut 3 B-C > 23 V 0 V: verify that the wires are soldered on the batterie pack and that no wire are cut. A few volts: the battery is discharged. (3) 783543 battery (a) Battery pack test B is the ground terminal. Test connection Residual capacity A-B sequence Discharge at 2.5 A down to 23 V result none 24-30-16 Page 5003 Jun 02/2008 COMPONENT MAINTENANCE MANUAL 20VR4D Test connection sequence result B-C Charge the battery at 0.4 A during 16 h Voltage must be less than to 31 V at the end of charge - Let the battery in place for 4 h none DB and AD Measure the voltage of the half battery section The difference of voltage between the 2 halves of battery must be less than 1 V. A-B Discharge at 0.8 A down to 20 V Discharging period must be 3 h or more. B-C Charge the battery at 28.5 V during 16 h none A-B Discharge the battery at 5 A down to 20 V Discharging period must be 25 min or more. B-C Charge the battery at 0.4 A during 16 h The battery is charged. Capacity test Charge at constant voltage Final charge (b) Wiring test Follow this test to verify the wiring. The test must be done with a fully charged battery. If a test fails, discard the battery. Test connection result analyses 1 B-A > 23 V 0 V: verify that the circuit breaker is pushed. Verify that the wires are soldered on the battery pack and that no wire are cut. A few volts: the battery is discharged 2 B-D About half the voltage of the battery 0 V: verify the fuse F, verify that the wire is not cut 3 B-C > 23 V 0 V: verify that the wires are soldered on the batterie pack and that no wire are cut. A few volts: the battery is discharged. (4) 785229 battery (a) Battery pack test B is the ground terminal. Test connection Residual capacity A-B sequence result Discharge at 2.5 A down to 23 V none 24-30-16 Page 5004 Jun 02/2008 COMPONENT MAINTENANCE MANUAL 20VR4D Test connection sequence result B-C Charge the battery at 0.4 A during 16 h Voltage must be less than to 31 V at the end of charge - Let the battery in place for 4 h none DB and AD Measure the voltage of the half battery section The difference of voltage between the 2 halves of battery must be less than 1 V A-B Discharge at 0.8 A down to 20 V Discharging period must be 3 h or more. B-C Charge the battery at 28.5 V during 16 h none A-B Discharge the battery at 5 A down to 20 V Discharging period must be 25 min or more. B-C Charge the battery at 0.4 A during 16 h The battery is charged. Capacity test Charge at constant voltage Final charge (b) Wiring test Follow this test to verify the wiring. The test must be done with a fully charged battery. If a test fails, discard the battery. Test connection result analyses 1 B-A > 23 V 0 V: verify that the circuit breaker is pushed. Verify that the wires are soldered on the battery pack and that no wire are cut. A few volts: the battery is discharged 2 B-D About half the voltage of the battery 0 V: verify the fuse F, verify that the wire is not cut 3 B-C > 23 V 0 V: verify that the wires are soldered on the batterie pack and that no wire are cut. a few volts: the battery is discharged 4 B-E > 23 V 0 V: Verify that the circuit breaker is pushed. Verify that the wires are soldered on the battery pack and that no wire are cut. A few volts: the battery is discharged. (5) 800864 battery (a) Battery pack test B is the ground terminal. Test connection Residual capacity A-B sequence Discharge at 2.5 A down to 23 V result none 24-30-16 Page 5005 Jun 02/2008 COMPONENT MAINTENANCE MANUAL 20VR4D Test connection sequence result B-C Charge the battery at 0.4 A during 16 h Voltage must be less than to 31 V at the end of charge - Let the battery in place for 4 h none DB and AD Measure the voltage of the half battery section The difference of voltage between the 2 halves of battery must be less than 1 V. A-E Discharge at 0.8 A down to 20 V Discharging period must be 3 h or more. B-C Charge the battery at 28.5 V during 16 h none B-E Discharge the battery at 5 A down to 20 V Discharging period must be 25 min or more. B-C Charge the battery at 0.4 A during 16 h The battery is charged. Capacity test Charge at constant voltage Final charge (b) Wiring test Follow this test to verify the wiring. The test must be done with a fully charged battery. If a test fails, discard the battery. Test connection result analyses 1 B-A > 23 V 0 V: verify that the 2.5 A circuit breaker is pushed. Verify that the wires are soldered on the battery pack and that no wire are cut. A few volts: the battery is discharged 2 B-D About half the voltage of the battery 0 V: verify the fuse F, verify that the wire is not cut 3 B-C > 23 V 0 V: verify that the wires are soldered on the batterie pack and that no wire are cut. a few volts: the battery is discharged 4 B-E > 23 V 0 V: verify that the 15 A circuit breaker is pushed. Verify that the wires are soldered on the battery pack and that no wire are cut. A few volts: the battery is discharged (6) 803551 battery (a) Battery pack test B is the ground terminal. Test connection Residual capacity A-B sequence result Discharge at 2.5 A down to 23 V none 24-30-16 Page 5006 Jun 02/2008 COMPONENT MAINTENANCE MANUAL 20VR4D Test connection sequence result B-C Charge the battery at 0.4 A during 16 h Voltage must be less than to 31 V at the end of charge - Let the battery in place for 4 h none DB and AD Measure the voltage of the half battery section The difference of voltage between the 2 halves of battery must be less than 1 V. A-B Discharge at 0.8 A down to 20 V Discharging period must be 3 h or more. B-C Charge the battery at 28.5 V during 16 h none A-B Discharge the battery at 2.5 A down to 20 V Discharging period must be 50 min or more. B-C Charge the battery at 0.4 A during 16 h The battery is charged. Capacity test Charge at constant voltage Final charge (b) Wiring test Follow this test to verify the wiring. The test must be done with a fully charged battery. If a test fails, discard the battery. Test connection result analyses 1 B-A > 23 V 0 V: verify that the circuit breaker is pushed. Verify that the wires are soldered on the battery pack and that no wire are cut. A few volts: the battery is discharged. 2 B-D About half the voltage of the battery 0 V: verify the fuse F, verify that the wire is not cut 3 B-C > 23 V 0 V: verify that the wires are soldered on the batterie pack and that no wire are cut. A few volts: the battery is discharged 24-30-16 Page 5007 Jun 02/2008 COMPONENT MAINTENANCE MANUAL 20VR4D PAGE INTENTIONALLY LEFT BLANK 24-30-16 BLANK COMPONENT MAINTENANCE MANUAL 20VR4D REPAIR 1. General As indicated in the CHECK chapter, defective parts for which no repair instructions are 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 tools 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. Standard tools Standard mechanic’s tools. C. Materials Not applicable 3. Repairs The only authorized repair applicable to the unit is: - Changing the battery pack (040). 24-30-16 Page 6001 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D REPAIR N°1 TASK 24-30-16-900-801 4. Changing the battery pack (040) A. General The battery pack (040) is a non reparable unit. B. Detailed procedure - Dissasemble the battery (refer to DISASSEMBLY Task.24-30-16-020-001) - 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 screw (010) ans the nuts (020) - Place the 6 screws (050). 24-30-16 Page 6002 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D ASSEMBLY TASK 24-30-16-871-810-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-24-30-16-400-802-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 24-30-16-400-801-A01 2. Assembly procedure A. Reason for the job Self-explanatory B. Job set-up information NOTE:You can use equivalent alternatives for the items in those lists. NOTE:Refer to SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMMABLES for full data of special tools in this list. (1) Tools, fixtures and equipment not applicable (2) Consumables Not applicable C. Job set-up Not applicable D. Procedure SUBTASK 24-30-16-420-001-A01 (1) Installation of the upper flange Assemble the upper flange withe the screw (010) ans the nuts (020) SUBTASK 24-30-16-970-001-A01 (2) Write the necessary information on: (a) the log book. E. Close up Not applicable 24-30-16 Page 7001 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D PAGE INTENTIONALLY LEFT BLANK 24-30-16 BLANK COMPONENT MAINTENANCE MANUAL 20VR4D FITS AND CLEARANCES TASK 24-30-16-400-802-A01 1. Torque table SUBTASK 24-30-16-820-005-A01 A. Torque table List of all applicable torque values needed to assemble and do servicing of the battery: NOTE:The values here are "lube torque" values. The threads should be lightly greased before to installation and applying torque. IPL FIG ITEM N° TORQUE VALUE NAME 010 050 N.m lbf.in Screw 2 ± 0.2 17.7 ± 0.2 screw 1 ± 0.1 8.85 ± 0.9 24-30-16 Page 8001 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D PAGE INTENTIONALLY LEFT BLANK 24-30-16 BLANK COMPONENT MAINTENANCE MANUAL 20VR4D SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMMABLES TASK 24-30-16-940-801-A01 1. Special tools, fixtures and equipment A. Special tools table 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 Discharge bench (constant current 0-5 A) Local purchase 1000 5000 1 T02 No special Power supply 0-40 V, 0-2 A Local purchase 1000 5000 1 T03 No special Multimeter range 2 V-50 V accuracy 1% Local purchase 1000 5000 1 TASK 24-30-16-13-941-801-A01 2. Consumables material A. Consumable materials table Material number M01 Description Soap Supplier code or name and address Local purchase 24-30-16 Page block where necessary 4000 Page 9001 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D PAGE INTENTIONALLY LEFT BLANK 24-30-16 BLANK COMPONENT MAINTENANCE MANUAL 20VR4D ILLUSTRATED PARTS LIST 24-30-16 Page 10001 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D PAGE INTENTIONALLY LEFT BLANK 24-30-16 BLANK COMPONENT MAINTENANCE MANUAL 20VR4D INTRODUCTION TASK 24-30-16-871-802-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 24-30-16 Page 10003 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D 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 24-30-16 Page 10004 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D (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 24-30-16 Page 10005 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D 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. 24-30-16 Page 10006 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D 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 24-30-16 Page 10007 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D PAGE INTENTIONALLY LEFT BLANK 24-30-16 BLANK COMPONENT MAINTENANCE MANUAL 20VR4D ALPHA NUMERICAL INDEX PART NUMBER 804750 AIRLINE STOCK NUMBER FIG NUMBER INDEX NUMBER 040 TOTAL REQUIRED 1 - Item not illustrated. 24-30-16 Page 10009 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D PAGE INTENTIONALLY LEFT BLANK 24-30-16 BLANK COMPONENT MAINTENANCE MANUAL 20VR4D DETAILED PARTS LIST 24-30-16 Page 10011 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D 010 030 040 030 020 122849 BATTERY Figure 10001/GRAPHIC 24-30-16-991-020 24-30-16 Page 10012 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D FIG. ITEM 01 - 001 010 020 030 040 PART NUMBER 122849 NP NP NP 804750 AIRLINE STOCK NUMBER NOMENCLATURE 1234567 Battery, 20VR4D Screw CHC M5x55, stainless steel Nut M5, stainless steel Flange Battery pack EFF. CODE UNITS PER ASSY RF 4 4 2 1 - Item not illustrated. 24-30-16 Page 10013 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D 010 030 040 030 060 020 050 135687 BATTERY Figure 10002/GRAPHIC 24-30-16-991-020 24-30-16 Page 10014 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D FIG. ITEM 02 - 001 010 020 030 040 050 060 PART NUMBER 135687 NP NP NP 804750 NP NP AIRLINE STOCK NUMBER NOMENCLATURE 1234567 Battery, 20VR4D 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 - Item not illustrated. 24-30-16 Page 10015 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D 010 030 040 030 060 020 050 783543 BATTERY Figure 10003/GRAPHIC 24-30-16-991-020 24-30-16 Page 10016 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D FIG. ITEM 03 - 001 010 020 030 040 050 060 PART NUMBER 783543 NP NP NP 804750 NP NP AIRLINE STOCK NUMBER NOMENCLATURE 1234567 Battery, 20VR4D 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 - Item not illustrated. 24-30-16 Page 10017 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D 010 030 040 030 060 020 050 785229 BATTERY Figure 10004/GRAPHIC 24-30-16-991-020 24-30-16 Page 10018 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D FIG. ITEM 04 - 001 010 020 030 040 050 060 PART NUMBER 785229 NP NP NP 804750 NP NP AIRLINE STOCK NUMBER NOMENCLATURE 1234567 Battery, 20VR4D 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 - Item not illustrated. 24-30-16 Page 10019 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D 010 030 040 030 060 020 050 800864 BATTERY Figure 10005/GRAPHIC 24-30-16-991-020 24-30-16 Page 10020 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D FIG. ITEM 05 - 001 010 020 030 040 050 060 PART NUMBER 800864 NP NP NP 804750 NP NP AIRLINE STOCK NUMBER NOMENCLATURE 1234567 Battery, 20VR4D 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 - Item not illustrated. 24-30-16 Page 10021 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D 010 030 040 030 020 050 803551 BATTERY Figure 10006/GRAPHIC 24-30-16-991-020 24-30-16 Page 10022 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D FIG. ITEM 06 - 001 010 020 030 040 050 PART NUMBER 803551 NP NP NP 804750 NP AIRLINE STOCK NUMBER NOMENCLATURE 1234567 Battery, 20VR4D Screw CHC M5x55, stainless steel Nut M5, stainless steel Flange Battery pack Screw M3x16, stainless steel EFF. CODE UNITS PER ASSY RF 4 4 2 1 6 - Item not illustrated. 24-30-16 Page 10023 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D PAGE INTENTIONALLY LEFT BLANK 24-30-16 BLANK COMPONENT MAINTENANCE MANUAL 20VR4D STORAGE (INCLUDING TRANSPORTATION) TASK 24-30-16-871-809-A01 1. Introduction A. General Storage inhibition and packaging guarantee the equipment against any attack by atmospheric agents. The figure and item numbers are those of the ILLUSTRATED PARTS LIST. B. Storage room Keep the batteries and spares in a dry and clean room. 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% ± 5% relative humidity atmosphere and to avoid to store a cell discharged TASK 24-30-16-871-809-A01. 2. Storage procedure A. Reason for the job Self explanatory B. Job set-up information (1) Tools, fixtures and equipment None (2) Consumables None C. Job set up SUBTASK 24-30-16-550-001-A01 (1) Preparation of the battery before storage (a) Put the battery in its usual position. D. Procedure SUBTASK 24-30-16-530-001-A01 (1) Packaging The batteries are usually put in cardboard boxes. For long storage or sea transportation, we recommend to put the batteries in a welded plastic container. In this type of container, with the recommanded temperature range, the batteries can be kept for 5 years. SUBTASK 24-30-16-550-002-A01 (2) Short term storage (Ref. Fig. 15001) (a) Place in a storage room. 24-30-16 Page 15001 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D 100 Charge retention 90 80 Available capacity (%C5Ah) 5°C 10°C 70 15°C 20°C 60 25°C 50 40 30 20 0 10 20 30 Rest time (days) 40 50 60 Short term storage Figure 15001/GRAPHIC 24-30-16-991-021 TASK 24-30-16-550-003-A01 (3) Long term storage (up 6 months) CAUTION:Saft Ni-Cd batteries may be stored in temperatures ranging from +5°C to +25°C (+41°F to +77°F) in a 65% ± 5% relative humidity atmosphere. The standard cardboard packaging is considered unsealed and allows 2 years of storage under the above conditions. No maintenance operation needs to be performed during the storage period. NOTE:Lead acid batteries must be stored in a different room (a) Operations 1 Place in a storage room. (b) Conditions 1 The storage life is 5 years, if using the following conditions : - Sealed packaging. - Temperature: + 5 °C to 25°C (41°F to 77°F). - Humidity: 65% ± 5%. - Isolated from detrimental agents : dirt, dust, clampness, vibration, corrosive atmosphere. 24-30-16 Page 15002 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D SUBTASK 24-30-16-540-001-A01 (4) Servicing after storage Charge the battery NOTE: After long term storage in open circuit, up 5 charge/discharge cycles are allowed to recover the initial performance of the battery. E. Close up Not applicable TASK 24-30-16-500-801-A01 3. Transportation procedure A. General 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. 24-30-16 Page 15003 May 14/2008 COMPONENT MAINTENANCE MANUAL 20VR4D PAGE INTENTIONALLY LEFT BLANK 24-30-16 BLANK