24-30-16 COMPONENT MAINTENANCE MANUAL WITH

(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
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Revision n°. 2
Jun 02/2008
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20VR4D
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Apr 15/
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SERVICE BULLETIN LIST
Service bulletin
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LIST OF EFFECTIVE PAGES
TITLE PAGE
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2
May 14/2008
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RECORD OF REVISIONS
1
2
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TESTING AND FAULT 1001
ISOLATION
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1003
1004
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SCHEMATIC AND
WIRING DIAGRAMS
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2002
2003
2004
2005
2006
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RECORD OF TEMPORARY REVISIONS
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SERVICE BULLETIN
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LIST OF EFFECTIVE
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DISASSEMBLY
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TABLE OF CONTENT
1
2
3
4
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CLEANING
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LIST OF ILLUSTRATIONS
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2
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INTRODUCTION
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2
3
4
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INSPECTION/CHECK 5001
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DESCRIPTION AND
OPERATION
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LIST OF EFFECTIVE PAGES
REPAIR
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ASSEMBLY
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7002
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FITS AND CLEARANCES
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8002
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SPECIAL TOOLS,
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FIXTURES,
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EQUIPMENT
AND CONSUMABLES
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ILLUSTRATED
PARTS LIST
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INTRO IPL
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ALPHA NUMERICAL
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DETAILED
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STORAGE (INCLU15001
DING TRANSPORTA- 15002
TION)
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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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
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SCHEMATIC AND WIRING DIAGRAMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2001
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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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
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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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
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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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
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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) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
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REPAIR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2. Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. Special tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Standard tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3. Repairs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
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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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
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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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
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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
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COMPONENT MAINTENANCE MANUAL
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E. Close up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15003
3. Transportation procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15003
A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15003
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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
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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.
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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
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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.
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(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.
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(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.
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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
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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
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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
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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.
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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.
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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
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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
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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.
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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 %.
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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
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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
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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
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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
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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
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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
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COMPONENT MAINTENANCE MANUAL
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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).
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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).
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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
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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
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COMPONENT MAINTENANCE MANUAL
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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
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ILLUSTRATED PARTS LIST
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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
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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
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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
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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
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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
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20VR4D
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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.
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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.
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20VR4D
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