COMPONENT MAINTENANCE MANUAL

F20/23XLM

HAWKER GmbH
Dieckstraβe 42
58089 Hagen
Germany

Tel: + 49 (0) 23 31 372 - 0

Fax: +49 (0) 23 31 372- 183

COMPONENT MAINTENANCE MANUAL

Doc No.: 4668252_03 F20/23XLM_Component_Maintenance_Manual_EN

WITH

ILLUSTRATED PART LIST

TYPE No.: F20/23XLM

PART No.: 4575126 – ( )

Issue No.: 3 24 – 38 – 51 TITLE PAGE – Page 1

JUL 20/18
COMPONENT MAINTENANCE MANUAL
F20/23XLM

24 – 38 – 51
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
HIGHLIGHTS

To: Holders of battery Type F20/23XLM ATA Reference 24 – 38 – 51 component

maintenance manual (CMM)

Herewith Revision No. 3 dated JUL 20/18

This revision of the component Maintenance Manual has the following modifications:

- Inclusion of COMMISSIONING section

- General update of CHECK section
- Update to ASSEMBLY AND STORAGE

CHAPTER PAGES ACTION

Title Title Page 1 Updated

Highlights HLGTS Page 1,2 Updated

Record of revisions RR – Page ½ Updated

List of effective pages LEP – Page 1,2 Updated

Table of Contents TC- Page 1 Updated

List of Figures LOF – Page 1 Updated

Introduction IP – Page 1/2 Updated

Description of Operation 1,2,4,5, 6 Updated

Testing and Fault Isolation 101 -103 Updated

24 – 38 – 51 HLGTS page-1
JUL 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
Commissioning 201 - 206 New

Disassembly 301, Updated

Cleaning 401-404 Updated

Check 501 - 524 Updated

Repair 601,603,605,606,608 Updated

Assembly and Storage 702 - 705 Updated / New

Special Tools, Fixtures and

901, 902 Updated
Equipment

24 – 38 – 51 HLGTS page-2
JUL 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
RECORD OF REVISIONS

INSERTED INSERTED
REVISION REVISION REVISION
REVISION No.
DATE No. DATE
BY DATE BY DATE

01 Nov 30/15

02 Mar 07/16

03 Jul 20/18

24 – 38 – 51 RR – Page 1/2
JUL 20/18
COMPONENT MAINTENANCE MANUAL
F20/23XLM

24 – 38 – 51
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
RECORD OF TEMPORARY REVISIONS

TEMPORARY REV
PAGE NO.: REVISION DATE BY DATE REMOVED BY
NO.:

24 – 38 – 51
RTR – Page 1/2
NOV 19/13
COMPONENT MAINTENANCE MANUAL
F20/23XLM
This page is intentionally left blank

24 – 38 – 51
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
SERVICE BULLETIN LIST

SERVICE
REVISION DATE BULLETIN INCORPORATED
BULLETIN
NUMBER INTO MANUAL
NUMBER

24 – 38 – 51 SB – Page 1/2
NOV 19/13
COMPONENT MAINTENANCE MANUAL
F20/23XLM

This page is intentionally left blank

24 – 38 – 51
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
LIST OF EFFECTIVE PAGES

CONTENTS PAGE DATE CONTENTS PAGE DATE

Title page 1 Jul 20/18 Description 7 Jull 20/18

and Operation
2 Blank 8 Blank

Record of 1 Jul 20/18 Testing and 101 Jul 20/18

Revisions fault isolation
2 Blank 102 Jul 20/18

Record of 1 Nov 19/13 103 Jul 20/18

Temporary
Revisions 2 Blank 104 Jul 20/18

1 Nov 19/13 Commissioning 201 Jul 20/18

Service bulletin
list 2 Blank 202 Jul 20/18

1 Jul 20/18 203 Jul 20/18

List of Effective
pages 2 Jul 20/18 204 Jul 20/18

1 Jul 20/18 205 Jul 20/18

Table of
contents 2 Nov 19/13 206 Jul 20/18

Disassembly 301 Jul 20/18

List of figures 1 Jul 20/18
302 Nov 19/13
2 Blank

Introduction 1 Jul 20/18 Cleaning 401 Jul 20/18

402 Jul 20/18

2 Blank
403 Jul 20/18
Description 1 Jul 20/18
and Operation 404 Blank
2 Jul 20/18
Check 501 Jul 20/18
3 Nov 19/13
502 Jul 20/18
4 Jul 20/18
503 Jul 20/18
5 Jul 20/18
504 Jul 20/18
6 Jul 20/18
505 Jul 20/18

24 – 38 – 51 LEP – Page 1
Jul 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
506 Jul 20/18 Assembly and 701 Nov 19/13
storage
507 Jul 20/18 702 Jul 20/18

508 Jul 20/18 703 Jul 20/18

509 Jul 20/18 704 Jul 20/18

510 Jul 2018 Special tools, 901 Jul 20/18

fixtures and
511 Jul 20/18 902 Jul 20/18
equipment
512 Jul 20/18 903 Nov 19/13

513 Jul 20/18 904 Nov 19/13

514 Jul 20/18 Illustrated TP 1001 Nov 19/13

Parts List
515 Jul 20/18
Introduction INTRO 1001 PG1 Nov 19/13
516 Jul 20/18
INTRO 1001 PG2 Nov 19/13
517 Jul 20/18
INTRO 1001 PG 3 Nov 19/13
518 Jul 20/18
Vendor code VC1 1001 PG1 Nov 19/13
519 Jul 20/18
index
520 Jul 20/18
Numerical NI/NUM 1001 Nov 19/13
521 Jul 20/18 Index PG1
Blank
522 Jul 20/18 NI/NUM 1001
PG2
523 Jul 20/18
Detailed Parts 1001 Nov 19/13
524 Blank list
1001-0 Nov 19/13
Repair 601 Jul 20/18
1001-1 Mar 07/16
602 Nov 19/13

603 Jul 20/18

604 Nov 19/13

605 Jul 20/18

606 Jul 20/18

607 Nov 19/13

608 Jul 20/18

24 – 38 – 51 LEP – Page 2
Jul 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
TABLE OF CONTENTS
PAGES

DESCRIPTION AND OPERATION

1 - Description 1
2 - Operation 4

TESTING AND FAULT ISOLATION

1 - Testing 101
2 – Fault isolation 101

COMMISSIONING 201

DISASSEMBLY

1 - Disassembly 301

CLEANING

1 – Light cleaning 401

2 – Extensive cleaning 401
3. – Protection of metallic parts 403/404

CHECK
1 - Maintenance checks 501
2 – Regular Maintenance 501
3 - Overhaul 509

REPAIR

A. - Reconditioning 601
B. - Testing reproducibility of performance 602
C. - Replacement of upper hexagonal nuts, spring washers and links 603
D. - Replacement of lower terminals nuts, caps and seals 604
E. - Replacement of cells 605
F. - Replacement of Insulation liners 606
G. - Replacement of the connector socket 607
H. - Replacement of Battery container and cover 608
I. - Replacement of non-compliant parts 608

ASSEMBLY AND STORAGE

1- Assemby 701
2- Storage 702

SPECIAL TOOLS, FIXTURES AND EQUIPMENT

1 – Special tools 901

24 – 38 – 51 TC – Page 1
Jul 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
2 – Materials 901

ILLUSTRATED PARTS LIST

1
Introduction 1001 1
Vendor code index VCI 1001 1
Numerical index NI / NUM 1
Detailed parts list 1001-1

24 – 38 – 51 TC – Page 2
LF – Page 1/2
Nov20/18
JUL 19/13
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
LIST OF FIGURES
PAGE

FIGURE 1 Figure 1 – F20/23XLM Battery 3

FIGURE 2 Electrolyte Adjustment 5

FIGURE 201 Commissioning 204 – 206

FIGURE 501 Regular Maintenance 505 – 508

FIGURE 504 Overhaul 515 – 523

FIGURE 901 Vent Plug spanner 902

FIGURE 902 Deep Discharge Resistor 902

FIGURE 903 Cell puller 903

FIGURE 904 Syringe 20ml 903

FIGURE 905 Hydrometer 904

FIGURE 1 F20/23XLM Battery, Exploded view 1001-0

24 – 38 – 51 LOF – Page 1/2

Jul 20/18
COMPONENT MAINTENANCE MANUAL
F20/23XLM

24 – 38 – 51
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
INTRODUCTION

1. GENERAL

This manual describes the processes for trained technicians to maintain the battery type F20/23XLM.
It includes the basic design features and details structured tasks for visual inspection, diagnostic,
testing, performance reconditioning, repair and the necessary care to maintain best endurance and
useful life of these batteries.

These instructions are written in accordance with the ATA No. 100 specification for the manufacturers’
technical manual, and adopt the following structure

1 -99 Description and Operation

101 – 199 Testing and fault isolation
201 – 299 Commissioning
301 – 399 Disassembly
401 – 499 Cleaning
501 – 599 Check
601 – 699 Repair
701 – 799 Assembly and Storage
801 – 899 (Not Applicable)
901 – 999 Special tool, fixtures and equipment
1001 – 1099 Illustrated parts lists

Note.

The instructions detailed in the manual are intended for the CHECK, REPAIR and OVERHAUL but not
for a release test of a battery which is temporarily unserviceable.

24 – 38 – 51 IP – Page 1/2
JUL 20/18
COMPONENT MAINTENANCE MANUAL
F20/23XLM

24 – 38 – 51
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
DESCRIPTION AND OPERATION

1. Description

A. General description of the battery.

The F20/23XLM battery is an assembly of twenty 23Ah extra low maintenance cells in a stainless steel
container fitted with a connector socket. (Type MS3509). These cells are connected in series to the
connector socket assembly (100) via rigid, highly conductive nickel-plated copper links. (230 to 270)

The battery container is designed with two carrying handles for transportation; two outlet pipes
supporting gas ventilation and cooling, and four latches for locking the cover on the container. Inside
the battery container the cells are held in place by partitions, liners and spacers and a gasket inside
the cover.

The battery is connected to the aircraft systems and is used:

 for APU Start, if necessary

 if a malfunction or failure occurs in the power supply system, in flight
 for powering aircraft systems on ground, (e.g. radio, interior lighting) if the external
electrical ground power supply is not connected to the aircraft system.

The 24 V battery is recharged in the aircraft via the 28VDC electrical system.

B. Data

(1) Technical data

 Nominal Voltage: 24 volts.

 Rated capacity: 23Ah at 1hour rate current (23A)
 Connector socket: MS 3509
 Electrolyte: Potassium Hydroxide solution with a density of 1.25kg/l to 1.27kg/l at 20°C
 Maximum dimensions at base of battery:
L = 252 mm (9.92in)
W = 247 mm (9.72in)
H = 208 mm (8.19 in)
 Battery weight: 24.5 Kg ± 1 kg ( 54.01lb ± 2.20Lb)

(2) Operation data

 Operating temperature range

 For float charge ( in service) -15°C to 55°C (5°F to 131°F)
 For discharge -30°C to 65oC (-22°F to 149°F)

24 – 38 – 51 Page 1
Jul 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
 Maximum instantaneous power:
 At +23oC (+77oF): 12V 15s 13.4kW
 At -18oC (+0oF): 12V 15 s 8.9kW

C. Detailed description

The F20/23XLM battery (01) consists of a stainless steel battery container (10) and cover (20)
containing twenty FP23XLM cells (40) fitted with a connector socket (100) type MS3509.
The exterior of the battery container (10) is fitted with two vent tubes, four latches, two carrying
handles and a connector socket (100) along with the battery identification information, which is
etched into the battery container.

The interior of the battery is lined with several pieces of insulating spacers (150 to 200). These are
assembled tightly between the cells (40) and the partitions of the battery container (10). Twenty
FP23XLM cells (40) are inserted between the partitions. These cells (40) are connected in series to
the connector socket assembly (100) via highly conductive rigid nickel-plated copper links. (230 to
270)

The battery cover (20) is fitted with four retainer clips, two handle retainers, a hold down bar and
a gasket (30) which is adhered to the underside of the cover (20).

24 – 38 – 51 Page 2
Jul 20/18
COMPONENT MAINTENANCE MANUAL
F20/23XLM

Figure 1 – F20/23XLM Battery

24 – 38 – 51 Page 3
Nov 19/13
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
2. Operation and basic requirements for battery’s airworthiness.

A. Charge

(1) Flight Charge

It is essential that the aircraft power supply voltage is adjusted and maintained to the
operating temperature of the battery, thus ensuring that the battery is charged under
optimum conditions preserving the longevity of the battery.

The charge voltage in the battery temperature range from 0°C to 30°C must be: 28.5V + 1V

(2) Maintenance Charge

Note: All battery maintenance shall be carried out in a dedicated battery workshop by trained
personnel following the instructions described.

Note: Remove the cover from the battery container prior to any constant current charges, to
avoid the accumulation of oxy-hydrogen in the battery box.

1. Constant Current Charge (I- Method)

The constant current charging method shall be used for commissioning and maintaining
batteries in the workshop to charge a fully discharged battery with a predefined current
and duration. EnerSys recommends a maintenance charging rate 0.2*I1 for 7 hours, or
0.1*I1 for 14 hours. The measurement of top of charge voltage shall be carried out 15 to
10 Minutes prior to the end of charge or after adjustment of the electrolyte level inside
cells; refer to para 3). Cells shall indicate a value equal above 1.58 V when measured at
electrolyte temperature between 18°C and 30°C. For the commissioning of new batteries,
or cells stored fully discharged for more than 3 months, and for reconditioning after
service an eight hours charge at 0.2*I1 is recommended.

2. Multi stage Charge (IUI-Method)

The IUI multistage charging method is a general method for rapid recharging batteries
with cells of an unknown, but balanced state of charge. EnerSys recommends a charging
rate of I1 until voltage has increased to 1.55V multiplied by the number of cells followed
by a constant current charge of 0.2*I1 for 2 hours. The measurement of top of charge
voltage shall be carried out 15 to 10 Minutes prior to the end of charge or after
adjustment of the electrolyte level inside cells; refer to para 3). Cells shall indicate a value
equal above 1.58 V when measured at electrolyte temperature between 18°C and 30°
Note: IUI multi stage charging shall not be applied at battery temperatures below 0°C
and on batteries stored for more than 3 month.

24 – 38 – 51 Page 4
Jul 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
3. Electrolyte level adjustments on cells

The adjustment of cell’s electrolyte level shall be done in the workshop, 15 to 10

minutes prior to the end of charge processes 1 or 2 always at 4.6 A by adding portions of
water until the level touches the low edge of the spacer.

Figure 2 – Electrolyte level

Remove any excessive water added prior to the end of charge with the syringe.

Note:

Never adjust electrolyte on battery cells standing idle in any State of Charge (SoC) and
during discharge.

1. Requirements for the electrolyte

The purity of water to adjust the cell’s electrolyte is specified in DIN EN 60993.

2. Spillage of electrolyte and insulation resistance

A spillage of electrolyte into the battery box will affect the insulation resistance of the
battery.

3. Avoid drying up of cells electrolyte by maintenance failures, cell defects and excessive
charge voltage.

Excessive decomposition of water always causes high electrolyte density which

stresses the structure of electrodes by swelling. While drying out of electrolyte liquid
cells might perform atypical and instable charge and discharge voltage values.

24 – 38 – 51
Page 5
Jul 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
B. Discharges

1. Capacity test at good inwards

The rated capacity is the minimum capacity, expressed in Ah, obtained from a fully charged
battery when discharged at the I1 rate to an EPV of 20V. At good inwards the rated capacity
of the battery is required.

2. “Capacity tests” during workshop maintenance

Cells in batteries returned from service should indicate a voltage of ≥ 1.0 V after 48 minutes
discharge at I1. Batteries with cells, which do not meet this requirement, should be subjected
to the scheduled maintenance and / or general overhaul. Cells in batteries being released to
service shall indicate a voltage of ≥ 1.0 V after 60 minutes discharge at I1.

3. Heavy discharge loads in service and impact.

Supplying high discharge current peaks and loads above 10 V in service, i.e. for starting, is
without any detrimental effects to the battery. A fully charged 24V battery with a nominal
rating of 23Ah can supply peak currents in excess of forty times of its nominal rated current.

Note:

Uncontrolled loads due to short circuits on the charged battery can be considered as
detrimental, if thermal damage occurs on components.

C. Insulation Resistance requirements for airworthy batteries

The Insulation resistance on a cleaned battery shall be ≥ 10 MΩ. If the Insulation resistance is
lower than 0.5 MΩ battery has to be cleaned and dried.

D. Precautions and Safety:

Observe the (local) instructions for battery use and position them visibly
near the battery.
Trained personnel must only carry out work on batteries
Read the Material Safety data sheet

Use protective glasses and wear safety clothing when working on batteries.
Adhere to the current accident prevention rules in the country where the
battery is used

No smoking
Do not expose batteries to naked flames, glowing embers or sparks, as it
may cause the battery to explode. Avoid sparks from cables or electrical
apparatus as well as electrostatic discharges.

24 – 38 – 51 Page 6
Jul 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

Avoid any contact of electrolyte with the eyes, open wounds / skin and
clothing.
Avoid ingestion of electrolyte. In case of skin contact with electrolyte and/
or ingestion of electrolyte as well as burns consult a doctor immediately or
“First Aid”, flush skin and eyes with plenty of water or a solution of boric
acid in water,
Remove electrolyte contaminated clothes, immediately wash in excess of
acetic water.

The caustic potash electrolyte solution is highly corrosive.

Avoid any spilling of electrolyte
Do not disassemble cells since cadmium and cadmium oxide is poisonous
and is believed to be carcinogenic. Nickel can cause serious skin allergic
reactions and skin irritations to nickel sensitive and exposed persons.

Batteries are heavy.

Use suitable transportation / lifting equipment
Battery vent tubes are not intended for use as lifting handles;

Risks of explosion and fire

Remove battery cover from container prior to any charges on ground (in
the workshop).
Do not use any inflammable organic solvents, CHC’s and mixtures of it for
cleaning
Do not dismantle cells.
Avoid conditions for electrical shocks by using insulated tooling. Electrical
short circuits and sparks may injure the operator, damage the battery and
ignite gases from charging.
Do not wear clothes with static fibres and metallic accessories (rings,
watches, belts jewellery) when working on batteries. Use a plastic brush
and antistatic cleaning cloth for dry wiping off adhesive dirt from the
battery.
Never place any conductive parts on metallic parts of the battery.
Do not block the battery outlet pipes with the liners.

Pay attention to the hazards that can be caused by batteries

24 – 38 – 51 Page 7/8
Jul 20/18
COMPONENT MAINTENANCE MANUAL
F20/23XLM

24 – 38 – 51
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
TESTING AND FAULT ISOLATION on the 24V F20/23XLM

1. Testing refer to “Check”

2. Fault Isolation

No. Faults Possible reasons Identification procedure Reference to Chapters

„Check“, either regular
1 Zero volt at Intercell links Voltage measurement maintenance or overhaul
battery broken,
connector Connector socket “DISASSEMBLY”
socket damage, “REPAIR”: section C
“REPAIR”: section G
„ASSEMBLY“
2 „Check“, either regular
Zero volt cell Short circuit Voltage measurement maintenance or overhaul

3 „DISASSEMBLY“
Minus volt Cell installed and Voltage measurement „REPAIR“ section D
cell operated in „ASSEMBLY“
reverse

„Check“, either regular

4 Reduced Low compression Capacity measurement maintenance or overhaul
discharge of the cells within
performance the battery „DISASSEMBLY“
„REPAIR“ section E
„ASSEMBLY“
Increased Measurement resistance „Check“, either regular
resistance due to adjustment of torques maintenance or overhaul
low torque „DISASSEMBLY“
connection of „REPAIR“ section C, if parts are
upper hexagonal corroded,
nuts „CLEANING“ if parts are heavily
contaminated
„ASSEMBLY“
cell installed in Voltage measurement As described in 3
reverse
corroded nuts, Visual inspection „Check“, either regular
links, washers, maintenance or overhaul
and connector „DISASSEMBLY“
socket parts „REPAIR“ section C
„ASSEMBLY“
Irreversibly aged Two capacity tests „Check“, either regular
cells of capacity maintenance or overhaul
and or end of „DISASSEMBLY“
charge voltage „REPAIR“ sections A, B, E
underperforming „ASSEMBLY“
the requirements

24 – 38 – 51 Page 101
1 Jul
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

No. Faults Possible reason Identification procedure Reference to Chapters

4 Imbalanced cells Two capacity tests „Check“, either regular
maintenance or overhaul,
„REPAIR“ section A, B
If necessary, „DISASSEMBLY“,
„REPAIR“ section E and
„ASSEMBLY“
5
Unusual high Cells dried out Voltage measurements after 10 „Check“, either regular
and instable minutes at constant current maintenance or overhaul
cell voltage at charge on the battery cells „DISASSEMBLY“
beginning of residually discharged before „REPAIR“ section E
charge „ASSEMBLY“

6 Immediately Battery fully Discharge „Check“, either regular

breakdown of discharged in maintenance or overhaul
discharge service
voltage
cell connector Voltage measurement Refer to no. 1 in column 1
broken or
damaged

Loose hexagonal Visual Inspection „Check“, either regular

nuts, broken maintenance or overhaul
spring washers „DISASSEMBLY“
„REPAIR“ section
„ASSEMBLY“

Connector socket Voltage measurement Refer to no. 1 in column 1

defect
Cell(s), dried out Also refer to no. 5 Refer to no 5 in column 1

7 cell top of Separator system Top of charge voltage „Check“, either regular
charge inside cell defect measurement at Constant current maintenance or overhaul
voltage of charge „DISASSEMBLY“
<1.58V cell „REPAIR“ section E
temperature > „ASSEMBLY“
30°C

24 – 38 – 51 Page 102
1 Jul
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
No. Faults Possible reasons Identification procedure Reference to Chapters
8 Leakage of Any leakage of Measurement of Insulation „Check“, either regular
electrolyte electrolyte, or resistance maintenance or overhaul
inside the conductive liquids Visual Inspection „DISASSEMBLY“
battery and moisture „CLEANING“
container inside the Select and carry out repair section
container. according to types of defects
„ASSEMBLY“
Leakage caused
by boiling
electrolyte due to
a cell’ Insulation
short circuit or
due to a battery
external short
circuit condition.

Leakage due to
defective vent
plugs.

Leakage due to
damaged cell
cases.

Leakage at pole
terminals on cell
covers.

Visual inspection „Check“, either regular

9 Visible signs Short circuited Measurement of Insulation maintenance or overhaul
on thermally cells caused a resistance „DISASSEMBLY“
damaged destructive Voltage measurement „CLEANING“
battery cells overcharge of the Select and carry out repair section
and battery according to types of defects
components „ASSEMBLY“

10 Battery Corrosion, poor Visual inspection, „Check“, either regular

connector connection, Measurement of surface maintenance or overhaul
and / or links melting loss due temperature
create to disconnecting Tighten the upper hexagonal nuts
excessive battery under with 5 Nm.
heat load In case of connector socket
damage refer to section 1 in this
table

24 – 38 – 51 Page 103
1 Jul
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
No. Faults Possible reason Identification procedure Reference to Chapters

11 Damaged or Mechanical Visual Inspection „Check“, either regular

distorted impact, maintenance or overhaul
battery transportation „DISASSEMBLY“
components damage Purchasing of a new battery box
Labelling the box
Battery handles „ASSEMBLY“
worn out

Function of
battery latches
impaired

Venting tubes
bended or
damaged

Battery container
distorted

Cover distorted

Gasket does not

adhere inside the
cover

12 Electrolyte Repeated cell’s Electrolyte density measurement “Check,” overhaul”

density too leakages on cells „DISASSEMBLY“
low If necessary, „REPAIR“ section E
„ASSEMBLY“

24 – 38 – 51 Page 104
1 Jul
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
COMMISSIONING

Commissioning (refer to fig 201) shall be applied to set new batteries and spare cells in service. It is also
applied to batteries being stored up to 5 years. Refer to “ASSEMBLE AND STORAGE”

1. Commissioning task

Attention

Never charge, discharge or adjust electrolyte on cells connected in series outside the battery case.

1. Remove the cover

2. Remove the caps from the main connector pins using insulated tools

3. Torque the upper hexagonal nuts to 5 Nm

4. Measure the insulation resistance with a MΩ-meter at 250 VDC between the positive+ pin of the
battery connector and the battery container.

Requirement: ≥ 10MΩ

If the battery is ≤ 10MΩ, stand it for 24 hours in dry atmosphere before repeating test. If battery is
still below 10MΩ after the 24 hours stand, investigate cause of insulation failure.

5. Connect the battery to the charge / discharge unit.

6. Undo the vent plugs and keep them aside on the cells mouth.

Attention:

Do not top up the cells with water at this stage

7. Check the battery temperature using either option [1] of [2].

Option [1.] - Electrolyte temperature in-side cell

• Place an insulated and electrolyte resistive thermometer in the centre most cell of the battery.
• Measure the electrolyte temperature, if the temperature is less than 31oC continue with step
11. If not, allow the battery to cool until a battery temperature of between +15°C and +30°C has
been achieved.

24 – 38 – 51 Page 201
5 Jul
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
Option [2.] - Battery Temperature

• Place an insulated temperature probe between cells at the centre of the battery
• Measure the battery temperature, if the battery temperature is less than 31oC continue with
step 8. If not, allow the battery to cool until a battery temperature of between +15oC and +30oC
has been achieved.

8. Charge the battery for 8 hours at I5

If necessary, adjust the electrolyte level of the cells 15 to 10 minutes prior to the end of charge at
4.6A.

Attention

Do not adjust electrolyte level further while battery is standing on open circuit.

9. For degassing cells, stand the battery for one hour on open circuit.

10. Discharge the 24V Battery at 23A to 20 V.

Record the cell voltages (column 3) in the log book.

Requirement: The voltage of each cell after 60 minutes must be equal or greater than 1.0 V

If new battery cells do not meet the requirement, contact the supplier

11. Soak the battery for a minimum of 8 hours at room temperature or until a battery temperature of
between +15°C and +30°C has been achieved.

12. Recharge the battery using either IUI Method [12.1] or I method [12.2].

Adjust the electrolyte level at a current of 4.6Amps (0.2*I1A) 15 minutes to 10 minutes prior to end
of the charge.

Afterwards measure the voltage on each cell prior to the end of charge

Requirement: cell voltage shall be ≥ 1.58 V

 Record the values in the log book

 If new cells fail this requirement, contact the supplier

Attention:

24 – 38 – 51 Page 202
5 Jul
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
 Don’t charge the battery with currents higher than 23A
 (Apply method 12.2 if battery temperature is low (-5°C to +15°C)
12.1 IUI method:
Charge the 24V battery at 23 Amps (I1A) until the voltage has increased to 31 Volts. After
approximately 1 hour charge, check that battery has reached the voltage level to switch to the second
current level of 4.6 Amps and charge for two hours at this current.

12.2 I method:
Charge the fully discharged battery for seven hours at 4.6Amps (0.2*I1A).
Requirement: cell voltage shall be ≥ 1.58 V
Record cells end of charge voltages.

13 Allow the battery to stand for 1 hour

14 Refit and tighten vent plugs

15 Torque the upper hexagonal nuts to 5 Nm

16 Re-fit the cover

17 Release the charged battery to service.

24 – 38 – 51 Page 203
5 Jul
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

Commissioning

[1.] Remove cover

[2.] Remove main

connecter dust cap

[3.] Tighten all

upper hexagonal
nuts to 5 Nm

[4.] Measure the

insulation resistance

Insulation No
Allow battery to
Resistance ≥ 10
stand for 24 hours
MΩ

Yes

Repeat Insulation
resistance
measurement

No
Insulation
Investigate cause of
Resistance ≥
insulation failure
10MΩ

[5.] Connect battery

charge / discharge
unit

[6.] Undo vent plugs

24 – 38 – 51 Page 204
5 Jul
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

[7.] Check the

battery
Temperature

No
Battery
Allow battery to
Temperature below
cool
31oC

Yes

[8.] Recharge
Battery

[9.] Stand battery

for 1 hour

[10] Capacity test

Battery

No
Cell voltages > 1.0V
Contact supplier
@ 60 minutes

Yes

[11.] Allow the

battery
temperature to fall
between 15oC– 30oC

24 – 38 – 51 Page 205
5 Jul
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

[12]. Recharge
Battery

[12.1] Method [12.2] Method

IUI Method I Method

[13.] Stand battery

for 1 hour

[14] Re-fit and

tighten vent plugs

[15.] Tighten all

upper hexagonal
nuts to 5 Nm

[16.] Refit cover

[17.] Release
battery

Figure 201 - Commissioning

24 – 38 – 51 Page 206
5 Jul
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
DISASSEMBLY

1. Disassembly (Refer to figure 1)

Note:
Refer to “TESTING AND FAULT ISOLATION” to find the condition of the component or possible
cause of malfunction. For extensive cleaning full disassembly is required. For repair only,
disassemble the battery to the degree necessary.

WARNING:

ENSURE THAT THE BATTERY IS FULLY DISCHARGED PRIOR TO DISASSEMBLY

A. Removal of cover

1. Disengage the four cover clamps from the battery container (10)
2. Remove the cover (20) from the container (10)

B. Removal of cell(s)
1. Tighten (lock) the vent plug (90) on each cell using the yellow vent plug spanner (Refer to
Figure 901 and “SPECIAL TOOLS, FIXTURES AND EQUIPMENT”)
2. Remove the upper hexagonal nuts (50) and spring washers (60)
3. Remove the intercell links (230 thru 270)
4. Identify cell positions within the battery container (10)
5. Remove all the cells (40) from the container (10) starting with the middle cell (40) of each
row using the insulated cell puller (refer to figure 903 and “SPECIAL TOOLS, FIXTURES AND
EQUIPMENT”, pulling the cell (40) in an upward direction

C. Removal of vent plugs

1. The vent plugs (90) with the special vent plug tool spanner (Refer to Figure 901 and
“SPECIAL TOOLS, FIXTURES AND EQUIPMENT”)
2. the vent plug (90) with together with the O-ring (90)

D. Removal of the liner

1. Identify liners positions (170,180,190,200,210,220) within the battery container

2. Remove the liners (170,180,190,200,210,220) from the container

E. Removal of connector socket

Note:
To reduce risk by damage due to short circuit remove an intercell link (240) between two
adjacent cells in the middle of the battery or links connecting battery rows.

24 – 38 – 51 Page 301
Jul 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
1. Remove the hexagonal nuts (50) and spring washers (60) that attach the intercell links
(270) to the connector socket (100)
2. Remove the two links (270)
3. Remove the four countersunk screws (110), four fan disk washers (120) and four sealing
rings (130) from the connector socket (100)
4. Remove the connector socket (100) and its sealing ring (140) from the battery container
(10)

24 – 38 – 51 Page 302
Nov 19/13
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
CLEANING

1. Light Cleaning

 Hand-tighten the vent plug on each cell with the spanner. Refer to Figure 901 and “SPECIAL
TOOLS, FIXTURES AND EQUIPMENT”)

 Clean the top of the cells with a plastic brush. Remove any dust, detached residues and salt
minerals by an oil-free compressed air source, or an industrial vacuum cleaner.

2. Extensive Cleaning (to be carried out if Insulation resistance of the battery is below 500 kΩ)

 Discharge the battery with 4.6A to 10 V and discharge each cell with a single resistor. (Refer to
Figure 902 and “SPECIAL TOOLS, FIXTURES AND EQUIPMENT”)

 Hand-tighten the vent plug on each cell with the spanner. Refer to Figure 901 and “SPECIAL
TOOLS, FIXTURES AND EQUIPMENT”)

 Disassemble the complete battery as detailed in “DISASSEMBLY” section of this CMM, followed
by cleaning of the following components:

A. Battery container and cover

 Clean the battery container and cover, by washing in a solution of soapy warm water.
Afterwards rinse with fresh water.

 Allow the battery container and cover to dry naturally, or supported by an oil free pressurized
air supply

 Check the battery container and cover for mechanical damage.

 Check the locks for malfunction.

 Check whether the gasket is securely fixed to the underside of the cover.

Note: Replace damaged Battery containers and / or cover; also replace cover if the gasket is
damaged or does not adhere to the cover.

 Coat the metallic surface of container and cover with silicone spray.

B. Insulating Packing pieces

 Clean the insulating packing pieces/liners, by washing in a solution of soapy warm water.
Afterwards rinse with fresh water

24 – 38 – 51 Page 401
2 Jul
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
 Allow the parts to dry naturally, or supported by an oil free pressurized air supply.

 Check the parts for any mechanical damage.

C. Connector socket, Hexagonal Nuts M8, Spring washers and links

 Clean the connector socket with wet cloth, only.

 Clean the cell connecting components by washing in a solution of soapy warm water.
Afterwards rinse with fresh water.

 Allow the parts to dry naturally, or supported by an oil free pressurized air supply.

 Check the parts for any mechanical and thermal damage and corrosion.

Note: Replace any defective parts

 Coat all replaced and cleaned metallic components with silicone spray (Refer to “SPECIAL TOOLS,
FIXTURES AND EQUIPMENT”, Part 2 MATERIALS)

D. Cells

Attention: [1] Prior to cleaning, ensure cells are closed with vents. [2] Do not submerge cells fully
under water

 Remove any traces of electrolyte and mineral salts from the terminals, cell case and cell cover,
by washing in a solution of soapy warm water. Afterwards rinse with fresh water.

 Allow cells to dry naturally, or supported by an oil free pressurized air supply

 Inspect the cells for any damage

 Inspect the nickel plating of pole terminals for damage

Note: Replace any defective and damaged cells

E. Vent plugs (Cleaning to be carried out, before measurement of response pressure)

 Remove the vent plugs from each cell.

 Clean all vent plugs, by washing in a solution of soapy warm water. Afterwards rinse with fresh
water.

24 – 38 – 51 Page 402
2 Jul
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
 Allow the vent plugs to dry naturally, or supported by an oil free pressurized air supply.

 Check the integrity of the seal on each vent plug and replace before testing vent plug pressure

 Check the operation of the vent plugs prior to refitting back into the cells using the following
steps:

Testing response pressure of vent plug:

a. Fix the vent plug with its O-ring into the test adapter.
b. Attach the adapter to the adjustable pressure-reducing device
c. Submerge the adapter and vent plug in a container of water.
d. Increase the pressure slowly.
e. Record the pressure when the vent valve opens (indicated by bubbles)
f. Stop the pressure source.
g. Remove the vent plug with its O-ring from the test adapter
h. Identify all vent plugs that do not open within 0.35 ± 0.2 bar.
i. Replace defective vent plugs and dispose them.

3. Protection of metallic parts

 Refer to “ASSEMBLY” on page 48 and carry out A), B), C) D)

Attention: Avoid the coating of the black seals, when using any coating agent.

Note: Silicone Spray Lubricant is neutral to the polymer parts assembled in the battery and it does
not attract dirt.

 coat all cleaned metallic components with silicone spray (Refer to “MATERIALS”)

24 – 38 – 51 PagePage 402
403/404
Nov 19/13
Jul 20/18
COMPONENT MAINTENANCE MANUAL
F20/23XLM

24 – 38 – 51
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
CHECK

1. Maintenance Checks.

In addition to the checks specified for airborne or ground use, in service EnerSys F20/23XLM
batteries require the following maintenance operations are adhered to:

 Regular Maintenance (refer “CHECK”, section 2)

 General Overhaul (refer to section 3)

2. Regular Maintenance

Regular Maintenance (refer to fig 501) shall be carried out every 12 months or 4000 OPH after the
installation of the maintained battery on to the aircraft. Tasks to be undertaken are listed below:

1. Remove the cover and check that the gasket is fully adhered to the cover. If any damage is
found, record defect and replace in accordance with the “REPAIR“ section “H”.

2. Inspect battery container and cover for any damage, signs of dents, cracks, splits,
overheating, short circuits, melting, dark spots and tarnish. If any damage is found, record
defect and replace in accordance with the „REPAIR“ section “H”

3. Inspect the connector socket for any signs of damage caused by arcing, faulty connection,
corrosion, loose parts and cracks in the connector socket casing. If any damage is found,
record defect and replace in accordance with the „REPAIR“ section “G”

4. Tighten any loose vent plug(s) and clean the top of the cells with a plastic brush. Remove
any detached deposits with an oil-free compressed air source or an industrial vacuum
cleaner.
5. Torque the upper hexagonal nuts to 5 Nm.
6. Measure the insulation resistance with a MΩ-meter at 250 VDC between the positive pin of
the battery connector and the battery container.

Requirement: ≥ 0.5MΩ

If R ≤ 0.5 MΩ, continue with General Overhaul, extensive cleaning

7. Measure and record cell voltages.

8. Identify cells with voltages lower than 1.2V

9. Undo the vent plugs and keep them aside on the cells mouth.

Attention:
Do not top up the cells with water at this stage

10. Connect the battery to the charge / discharge unit.

24 – 38 – 51 Page 501
1 Jul
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

11. Check the battery temperature using either option [1] of [2].

Option [1.] - Electrolyte temperature in-side cell

• Place an insulated and electrolyte resistive thermometer in the centre most cell of
the battery.

• Measure the electrolyte temperature, if the temperature is less than 31oC continue
with step 12. If not, allow the battery to cool until a battery temperature of between
+15oC and +30oC has been achieved.

Option [2.] – Battery Temperature

• Place an insulated temperature probe between cells at the centre of the battery

• Measure the battery temperature, if the battery temperature is less than 31oC
continue with step 12. If not, allow the battery to cool until a battery temperature
of between +15oC and +30oC has been achieved.

12. Discharge the 24 V battery at 23A to 20 V. (pay particular attention to previously marked
cell(s) in step 8)

Requirement: after 48 minutes discharge, the voltage of each cell ≥ 1.0V.

If the requirement is not met, then continue with “Reconditioning procedure” in „REPAIR“
section A and B

13. Connect 1 Ohm/2watt resistor (Fig. 902) for 16 hours (minimum) up to 72 hours (maximum
between the positive and negative terminal of each cell.

14. Recharge the battery using 14.1 I method.

Attention:
Don’t charge the battery with currents higher than I1

Adjust the electrolyte level 15 minutes to 10 minutes prior to end of the charge at a current
of 4.6A (0.2* I1 ) A.

Afterwards measure the voltage on each cell prior to the end of charge.

Requirement: Cell voltage shall be ≥ 1.58 V

Record cells end of charge voltages.

Identify cells ≤ 1.58V for replacement. Refer to „REPAIR“ section E

24 – 38 – 51 Page 502
1 Jul
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
14.1 I method:

Charge the fully discharged battery for eight hours at 4.6Amps (0.2*I1A)

15. Allow the battery to stand for one hour to support the escapes of charging gases from cells.

16. Discharge the 24 V battery at 23 Amps to 20 V

Requirement:
The voltage of each cell after 60 minutes must be equal / greater than 1.0V.
If necessary, Identify cells for replacement. (Refer to „REPAIR“ section (E))

17. Soak the battery for a minimum of 8 hours at room temperature or until a battery
temperature of between +15oC and +30oC has been achieved

18. Recharge the battery using either IUI Method or I method.

Adjust the electrolyte level at a current of 4.6Amps (0.2*I1A) 15 minutes to 10 minutes

prior to end of the charge.
Afterwards measure the voltage on each cell prior to the end of charge

Requirement: cell voltage shall be ≥ 1.58 V

Record cells end of charge voltages.

Mark cells for replacement

Attention:
Don’t charge the battery with currents higher than 23A, when using IUI-method

IUI method:

Charge the 24V battery at 23 Amps (I1A) until the voltage has increased to 31 Volts. After
approximately 1 hour charge, check that battery has reached the voltage level to switch to the
second current level of 4.6 Amps and charge for two hours at this current.

I method:
Charge the fully discharged battery for seven hours at 4.6Amps (0.2*I1A).

19. Allow the battery to stand for one hour to support the escapes of charging gases from cells.

20. Re fit and tighten the vent plugs

24 – 38 – 51 Page 503
1 Jul
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

21. Torque the upper hexagonal nuts to 5 Nm.

22. Re fit the cover

23. Release the battery to service

24 – 38 – 51 Page 504
1 Jul
COMPONENT MAINTENANCE MANUAL
F20/23XLM
Regular
Maintenance

[1.] Remove cover

and inspect Gasket

Yes
Refer to REPAIR
Defects found
section “H”

No

[2.] Inspect Battery

Container & Cover

Yes
Refer to REPAIR
Defects found
section “H”

No

[3.] Inspect
Connector

Yes
Refer to REPAIR
Defects found
section “H”

No

[4.]Tighten vent
Plugs and clean top
of cells

[5.] Tighten all

upper hexagonal
nuts to 5 Nm

24 – 38 – 51 505
Page 503
Jul 20/18
Nov 19/13
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

[6.] Measure the

insulation resitance

No
Insulation
Refer to GENERAL
Resistance ≥
OVERHAUL
0.5MΩ
Yes

[7.]Measure &
record Cell voltages

[8.] Identify cells

lower than 1.2 V

[9.] Undo vent plugs

[10.] Connect
battery to charge /
Discharge unit

[11.] Check the

battery
Temperature

No
Battery
Allow battery to
Temperature below
cool
31oC

Yes

24 – 38 – 51 Page 506
6 Jul
COMPONENT MAINTENANCE MANUAL
F20/23XLM

[12.] Discharge the

battery

No
Refer “REPAIR”
Cell voltages > 1.0V
section
@ 48 minutes
“Reconditioning”

Yes

[13.] Deep discharge

the battery, connect
1 Ohm/2watt
resistor

[14.] Recharge
Battery

[14.1] Method
I Method

[15.] Stand battery

for 1 hour

[16] Capacity test

Battery

24 – 38 – 51 Page 507
6 Jul
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

Cell voltages > 1.0V No Refer “REPAIR”

@ 60 minutes Section E

Yes

[17.] Allow the

battery
temperature to fall
between 15oC– 30oC

[18]. Recharge
Battery

[18.1] Method [18.2] Method

IUI Method I Method

[19.] Stand battery

for 1 hour

[20] Re-fit and

tighten vent plugs

[21.] Tighten all

upper hexagonal
nuts to 5 Nm

[22.] Refit cover

[23.] Release
battery

Figure 501 – Regular Maintenance

24 – 38 – 51 Page 508
6 Jul
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
3. General Overhaul (refer to fig 502) shall be carried out in intervals of 2 year. Tasks to be
undertaken are listed below

1. Remove the cover and check that the gasket is fully adhered to the cover. If any damage is
found, record defect and replace in accordance with the „REPAIR“ section (H).

2. Inspect battery container and cover for any damage, signs of dents, cracks, splits,
overheating, short circuits, melting, dark spots and tarnish. If any damage is found, record
defect and replace in accordance with the „REPAIR“ section (H).

3. Inspect the connector socket for any signs of damage caused by arcing, faulty connection,
corrosion, loose parts and cracks in the connector socket casing. If any damage is found,
record defect and replace in accordance with the „REPAIR“ section (G)

4. Tighten any loose vent plugs and clean the top of the cells with a plastic brush. Remove
any detached deposits with an oil-free compressed air source, or an industrial vacuum
cleaner

5. Torque the upper hexagonal nuts to 5 Nm

6. Measure and record cell voltages.

7. Identify cells with voltages lower than 1.2V

8. Undo the vent plugs and keep them aside on the cells mouth.

Attention:
Do not top up the cells with water at this stage

9. Connect the battery to the charge / discharge unit.

24 – 38 – 51 Page 509
Jul 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

10. Check the battery temperature using either option [1] of [2].

Option [1.] - Electrolyte temperature in-side cell

• Place an insulated and electrolyte resistive thermometer in the centre most cell of
the battery.

• Measure the electrolyte temperature, if the temperature is less than 31oC continue
with step 11. If not, allow the battery to cool until a battery temperature of between
+15oC and +30oC has been achieved.

Option [2.] - Battery Temperature

• Place an insulated temperature probe between cells at the centre of the battery

• Measure the battery temperature, if the battery temperature is less than 31oC
continue with step 11. If not, allow the battery to cool until a battery temperature
of between +15oC and +30oC has been achieved.

11. Discharge the 24 V battery at I1 to 20V. (pay attention to cells previously marked at step 8.

Requirement: The voltage of each cell after 48 minutes discharge at I1 should be equal or
greater than 1.0 V.

If cells indicate voltage above 0V but below 1 V subject the battery to Reconditioning

If cells indicate 0V replace in accordance with Repair section E.

12. Connect 1 Ohm/2watt resistor (Fig. 902) for 16 hours (minimum) up to 72 hours (maximum
between the positive and negative terminal of each cell.

13. Tighten all vent plugs using the vent plug spanner (Refer to Figure 901 and “SPECIAL
TOOLS, FIXTURES AND EQUIPMENT”)

14. Disassemble the battery (Refer to “DISASSEMBLY”)

15. Extensively clean the battery components not replaced in step above (Refer to
„CLEANING“, section 2, A,B,C,D,E)

24 – 38 – 51 Page 519
Jul 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

16. Inspect all upper hexagonal nuts, washers and intercell links for any signs of damage or
corrosion. Dispose and replace any defective components. (Refer to „REPAIR“, section (C))

17. Inspect all cells for signs of thermal damage and discoloration. Dispose and replace any
defective cell(s). (Refer to REPAIR“ section (E))

Note: It is recommended to replace the whole sets of cells if more than 6 cells from the
original set were (are to be) replaced.

18. Inspect all insulating packing pieces/liners for any signs of damage. Dispose and replace
any damaged insulating packing pieces/liners. (Refer to „REPAIR“ section (F))

19. Re-Assembly of the battery (Refer to “Assembly”)

20. Measure the insulation resistance with a MΩ-meter at 250 VDC between the positive pin
of the battery connector and the battery container.

Requirement: ≥ 10MΩ

If the battery is ≤ 10MΩ, stand it for 24 hours in dry atmosphere before repeating test. If
battery is still below 10MΩ after the 24 hours stand, investigate cause of insulation failure.

21. Remove the battery cover.

22. Connect the battery to the charge/discharge unit.

23. Undo the vent plugs together with the O-rings.

24. Recharge the battery using eitherI method.

Note: If any cells have been replaced, recharge the battery using I method only.

Adjust the electrolyte level at a current of 4.6Amps (0.2*I1A) 15 minutes to 10 minutes

prior to end of the charge.

Afterwards measure the voltage on each cell prior to the end of charge

24.1 I method:

Charge the fully discharged battery for eight hours at 4.6Amps (0.2*I1A).

24 – 38 – 51 Page 511
2 Jul
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

Requirement: cell voltage shall be ≥ 1.58 V

Record cells end of charge voltages.

Mark cells for replacement at step 26.

25. Allow the battery to stand for 1 hour

26. Discharge the 24 V battery at I1 to 20 V

Requirement: The voltage of each cell after 60 minutes must be equal / greater than 1.0V.

Identify cells for replacement. (Refer to „REPAIR“ section (E))

27. Soak the battery for a minimum of 8 hours at room temperature or until a battery
temperature of between +15°C and +30°C has been achieved

28. Recharge the battery using either IUI Method or I method.

Note:

Do no adjust electrolyte level!

Measure the voltage on each cell prior to the end of charge

Requirement: cell voltage shall be ≥ 1.58 V

Record cells end of charge voltages.

Mark cells for replacement

Attention:
Don’t charge the battery with currents higher than 23A, when using IUI-method

28.1 IUI method:

Charge the 24V battery at 23 Amps (I1A) until the voltage has increased to 31 Volts. After
approximately 1 hour charge, check that battery has reached the voltage level to switch to the
second current level of 4.6 Amps and charge for two hours at this current.

28.2 I method:

Charge the fully discharged battery for seven hours at 4.6Amps (0.2*I1A).

24 – 38 – 51 Page 512
2 Jul
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

29. If electrolyte was found in the battery case after disassembly, measure the electrolyte
density of all cells 15 minutes after the recharge in step 28 with a hydrometer or an
electronic densimeter and the cell temperature inside one cell in the middle of the battery.

Requirement: 1.25kg/L ≤ Density ≤ 1.27kg/L at 20°C ± 5°C.

Record the results and the test temperature.

Replace cell(s) with densities lower than 1.25 kg/L. “REPAIR“, section (E)

30. Allow the battery to stand for one hour to support the escapes of charging gases from cells

31. Discharge the 24 V battery at I1 to 20 V

Requirement: The voltage of each cell after 60 minutes must be equal / greater than 1.0V.
Identify cells for replacement. (Refer to „REPAIR“ section (E))

32. Soak the battery for a minimum of 8 hours at room temperature or until a battery
temperature of between +15oC and +30oC has been achieved

33. Recharge the battery using either IUI Method or I method.

Requirement: cell voltage shall be ≥ 1.58 V

Attention:
Don’t charge the battery with currents higher than 23A, when using IUI-method

33.1 IUI method:

Charge the 24V battery at 23 Amps (I1A) until the voltage has increased to 31 Volts. After
approximately 1 hour charge, check that battery has reached the voltage level to switch to the
second current level of 4.6 Amps and charge for two hours at this current.

33.2 I method:
Charge the fully discharged battery for seven hours at 4.6Amps (0.2*I1A).

34. Allow the battery to stand for one hour to support the escapes of charging gases from cells

24 – 38 – 51 Page 513
2 Jul
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

35. Clean and test the vent plugs in accordance with "Cleaning".

36. Refit and tighten vent plugs

37. Torque the upper hexagonal nuts to 5 Nm

38. Re-fit the cover

39. Measure the insulation resistance with a MΩ-meter at 250 VDC between the positive pin
of the battery connector and the battery container.

Requirement: ≥ 10MΩ

If the battery is ≤ 10MΩ, stand it for 24 hours in dry atmosphere before repeating test. If
battery is still below 10MΩ after the 24hours stand, identify and remove the insulation
failure in the wiring system

40. Release the charged battery to service.

24 – 38 – 51 Page 514
2 Jul
COMPONENT MAINTENANCE MANUAL
F20/23XLM

General Overhaul

[1.] Remove cover

and inspect Gasket

Yes
Refer to REPAIR
Defects found
section “H”

No

[2.] Inspect Battery

Container & Cover

Yes
Refer to REPAIR
Defects found
section “H”

No

[3.] Inspect
Connector

Yes
Refer to REPAIR
Defects found
section “H”

No

[4.]Tighten vent
Plugs and clean top
of cells

[5.] Tighten all

upper hexagonal
nuts to 5 Nm

24 – 38 – 51 Page
Page 510
511
515
Nov
Nov 19/13
19/13
Jul 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

[6.]Measure &
record Cell voltages

[7.] Identify cells

lower than 1.2 V

[8.] Undo vent plugs

[9.] Connect battery

to charge /
Discharge unit

[10.] Check the

battery
Temperature

No
Battery
Allow battery to
Temperature below
cool
31oC

Yes

24 – 38 – 51 Page 516
Jul 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

[11.] Discharge the

battery

No No Refer “REPAIR”
Cell voltages > 1.0V Cell voltage is
section
@ 48 minutes zero volts
“Reconditioning”

Yes Yes

[12.] Deep discharge Refer “REPAIR”

battery. section “F”

[13.]Tighten all vent

plugs

[14.]Disassemble
battery

[15.] Extensively
clean battery
components

24 – 38 – 51 Page 517
Jul 20/18
COMPONENT MAINTENANCE MANUAL
F20/23XLM

[16.] Inspect upper

Nuts, washers
&intercell links for
signs of damage or
corrosion

Yes
Refer to REPAIR
Defects found
section “C”

No

[17.] Inspect cells

for signs of damage
or discolouration

Yes
Refer to REPAIR
Defects found
section “E”

No

[18.] Inspect
insulating packing
pieces / liners for
sign of damage

Yes
Refer to REPAIR
Defects found
section “F”

No

[19.] Re-assemble
battery

24 – 38 – 51 Page 518
Jul 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

[20.] Measure the

insulation resistance

No
Insulation
Allow battery to
Resistance ≥ 10
stand for 24 hours
MΩ
Yes

Repeat Insulation
resistance
measurement

No
Insulation
Investigate cause of
Resistance ≥
insulation failure
10MΩ
Yes

[21.] Remove
battery cover

[22.] Connect
battery charge /
discharge unit

24 – 38 – 51 Page 519
Jul 20/18
COMPONENT MAINTENANCE MANUAL
F20/23XLM

[23.] Remove vent

plugs.

[24.] Recharge
Battery

[24.1] Method
I Method

[25.] Stand battery

for 1 hour

[26] Discharge the

Battery

24 – 38 – 51 Page 520
Jul 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
F

Cell voltages ≥ 1.0V No Refer “REPAIR”

@ 60 minutes Section E

Yes

[27.] Allow the

battery
temperature to fall
between 15oC– 30oC

[28]. Recharge
Battery

[28.1] Method [28.2] Method

IUI Method I Method

Yes Cells Replace cell with a

[29.] Electrolyte No
Density between density lower than
noticed during
1.25kg/l – 1.27 kg/l 1.25Kg/l Refer
disassembly
@ 20oC “REPAIR” Section (E)

No Yes

[30.] Recharge
Battery using
I method

[31]. Discharge
Battery

No
Cell voltages ≥ 1.0V Refer “REPAIR”
@ 60 minutes Section E

Yes

G H

24 – 38 – 51 Page 521
Jul 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

G H

[32.] Allow the

battery
temperature to fall
between 15oC– 30oC

[33]. Recharge
Battery

[33.1] Method [33.2] Method

IUI Method I Method

[34.] Stand battery

for 1 hour

[35.] Clean and test

vent plugs

[36] Re-fit and

tighten vent plugs

24 – 38 – 51 Page 522
Jul 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

[37.] Tighten all

upper hexagonal
nuts to 5 Nm

[38.] Refit cover

[39.] Measure the

insulation resistance

No
Insulation
Allow battery to
Resistance ≥ 10
stand for 24 hours
MΩ
Yes

Repeat Insulation
resistance
measurement

No
Insulation
Investigate cause of
Resistance ≥
insulation failure
10MΩ
Yes

[40.] Release
battery

Figure 502 – General Overhaul

24 – 38 – 51 Page 523/524
Jul 20/18
COMPONENT MAINTENANCE MANUAL
F20/23XLM

24 – 38 – 51
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
REPAIR

A) Reconditioning of imbalanced cells indicating reversible capacity decline

Note:
For charged batteries from service containing cells returning less than 80% of its nominal capacity this
reconditioning is advised. One cycle consisting of deep discharge, recharge and capacity test is sufficient
to meet the capacity requirement. Two cycles can be carried out to proof the reproducibility of cell’s
performance. If no improvement in capacity output relative to the previous measurement(s) could be
achieved the cells are irreversibly aged and shall be replaced.

1. Discharge the 24V battery with rates between 0.2* I1 and I1 to 20V.
 Connect 1 Ohm/2watt resistor (Fig. 902) for 16 hours (minimum) up to 72 hours (maximum between the
positive and negative terminal of each cell.

2. Charge the battery for 8 hours at 0.2* I1.

 If necessary, adjust the electrolyte level of the cells 10 to 15 minutes prior to the end of charge.
 Measure the cell voltages prior to the end of charge
 Identify cells for replacement after Discharge in section 4
 Record the data in the logbook

3. Stand the battery for 1 hour to support escapes of charge gasses

4. Discharge the 24V battery at I1 to 20V.

Requirement: The voltage of each cell after 60 minutes must be equal / greater than 1 Volt.
Identify cells for replacement. (Refer either to „REPAIR“ section (E) or test reproducibility of performance in
accordance with „REPAIR“ section B)

5. Record the cell voltages in the log book.

Record in the log book whether the battery has passed or failed

6. (For testing reproducibility of data on the reconditioned battery, carry out the process-steps in section B below.)

If reconditioning was started from regular maintenance and cells met requirement of section 4 above continue
in regular maintenance at step 17. If cells failed in section 4 and have been replaced continue at step 14.

If reconditioning was started from general overhaul and cells met requirement of section 4, or failed and have
been replaced always continue at overhaul in step 12.

24 – 38 – 51
Page 601
Jul 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
B) Testing reproducibility of performance

1. Soak the battery discharged in section A to ambient room temperature, which can take up to 8 hours

2. Charge the 24V battery with 23 A to 31V and charge for 2 hours at 4.6A
Or
Charge the battery for 7 hours at I5.
 If necessary, adjust the electrolyte level of the cells 10 to 15 minutes prior to the end of charge.
 Measure and record the cell voltages prior to the end of charge
Requirement: ≥1.58 Volt per cell.
 Identify cells for replacement after Discharge in section 8

3. Stand the battery for 1 hour

4. Discharge the 24V battery at I1 to 20V.

Requirement: The voltage of each cell after 60 minutes must be equal / greater than 1 Volt.
Identify cells for replacement. „REPAIR“ Section (E)

5. Compare discharge time until battery voltage passed 20 V; Time measured in section B shall be >= Time
measured in section A. and note results in the log book.

6. Record in the battery log book whether the battery has passed or failed

7. If the reconditioned battery cells met the requirements, continue in the original start routines of “Check, either
“regular maintenance step 10” or in “General overhaul step 12”

24 – 38 – 51 Page 602
Nov 19/13
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
C) : Replacement of upper hexagonal nuts, spring washers and links

ATTENTION:
• Spare parts used for any repair listed below have to comply with the IPL
• Before disassembly, discharge the battery with 0.2*I1 to 0.5 V per cell.
.
1. Remove any corroded hexagonal nuts (50), spring washers (60) and intercell links (230, 240, 250, 260, 270) from
the cells (40) and dispose them

2. Fit new intercell links (230, 240, 250, 260, 270), spring washers (60) and hexagonal nuts (50).

3. Tighten the upper hexagonal nuts (50) on the pole terminals with the torque value of 5.0 Nm

24 – 38 – 51 Page 603
Jul 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
D) Replacement of lower hexagonal nuts, caps and seals

Note
Only in case of corrosion and or leakage replacement of lower hexagonal nuts, caps and seals can be considered

ATTENTION:
• Spare parts used for any repair listed below have to comply with the IPL.
• Before disassembly, discharge the battery with 0.2*I1 to 0.5 V per cell
• To avoid potential leakage of electrolyte replace one lower hexagonal nut and then the other, cap and seal on one
pole then the other pole, not both simultaneously
• Lower Hexagonal nuts, sealing caps, and seals should be replaced in pairs

1. Undo and remove the upper hexagonal nuts (50).

2. Remove the washers (60) and intercell links (230, 240, 250, 260, 270) from the cells (40)

3. Undo one lower hexagonal nut and dispose. (50)

4. Undo and dispose the spacer (70) and seal (80).

5. Replace the disposed parts by new parts in accordance with the IPL.

6. Torque the lower hexagonal nut (50) with 4 Nm

7. Repeat step 3 to 6 to replace the other lower hexagonal nut, sealing cap and seal of the cell.

8. Check the integrity of the seals. (80)

In case of fail replace the cell in accordance with Repair section

9. Place the intercell links (230, 240, 250, 260, 270) and spring washers (60) on the terminals.

10. Fix and torque the upper hexagonal nuts (50) with 5 Nm

11. Record the action in the log book

24 – 38 – 51 Page 604
Nov 19/13
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
E) Replacement of cells

ATTENTION:
• Spare parts used for any repair listed below have to comply with the IPL
• Before disassembly, discharge the battery with 0.2* I1 to 0.5 V per cell
• If six cells in a 24V battery have been replaced from the original set, replace all cells and defective battery
components and carry out commissioning charge!
• Before disassembling cells release any pressure build up in the cells by loosening vent plugs and afterwards tighten
the vent plugs with the spanner.
• If there is evidence of thermal damage, remove all cells and inspect.

1. Remove upper hexagonal nuts (50), spring washers (60), and links (230, 240, 250, 260, 270) in order to remove
defective cell(s).

2. Pull out the defective cell (40) using cell puller, refer to and “SPECIAL TOOLS, FIXTURES AND EQUIPMENT”,
Figure 903

3. Dispose replaced cell(s) (40) in accordance with local regulations.

4. Fit new cell(s) (40) into the block of cells.

5. Refit links (230, 240, 250, 260, 270), washers and upper hexagonal nuts.

6. Fit and torque the upper hexagonal nuts (50) with 5 Nm

7. Record the action and the serial-no. of the new installed cells (50) in the log book

24 – 38 – 51 Page 605
5 Jul
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
F) Replacement of Insulation liners

ATTENTION
• Any spare parts used for repair listed below must comply with the IPL
• Due to tolerances in cell thicknesses the amount of plastic liners can deviate from the drawing in the IPL.
• Before disassembling cells release potential pressure build up in the cells by loosening vent plugs and afterwards
tightening the vent plugs in the threads.
• The cells, reassembled together with new liners and empty containers shall be packed sufficiently to ensure
there is no movement of cells within the battery container
• Before disassembly, discharge the battery with 0.2* I1 to 0.5 V per cell

1. Undo and remove all upper hexagonal nuts on the cells (50).

2. Remove spring washers (60) and intercell links (230, 240, 250, 260, 270).

3. Note positions of the cells (40) in the container (10) and remove them afterwards.

4. Note positions of insulation liners (170, 180, 190, 200, 210, 220) in the container (10) and remove
them afterwards

5. Install new insulating (170, 180, 190, 200, 210, 220) liners in its correct place

6. Place cells (40) with correct polarity into their original position in the battery container (10)

7. Refit links 230, 240, 250, 260, 270) and spring washers (60) on pole terminals

8. Tighten and torque the upper nuts (50) with 5 Nm

24 – 38 – 51 Page 606
5 Jul
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

G) Replacement of the connector socket

ATTENTION
• Any spare parts used for repair listed below must comply with the IPL

1. Remove the hexagonal nuts (150) and spring washers(160) that attaching intercell links (270) from
the connector socket (100)

2. Remove the two links (270)

3. Remove the four screws (110) and four fan disk washers (120) from the connector socket (100)

4. Remove the connector socket (100) and four sealing rings (130)

5. Remove the sealing ring (140),

6. Place new sealing ring (140) over the rear of connector socket casing (100)

7. Place the four fan disk washers (120) and four countersunk screws (110) into the fixing holes of the
connector socket casing (100)

8. Fix one sealing ring (130) onto each of the four countersunk screws (110).

9. Place the connector socket (100)with attaching parts (110,120,130,140) into the battery container
(10) and tighten to 2Nm

10. Place the links (270), spring washers (160) and tighten the upper hexagonal nuts (150) to 5 Nm.

24 – 38 – 51 Page 607
Nov 19/13
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

H) Replacement of Battery container and cover

1. Record the data from the Logbook or the battery label.

2. Send the data together with an order for a new container and cover to the supplier.

3. On receipt of new battery container and cover disassemble the battery

4. For the components to be re-used proceed according Paragraph “CLEANING” section 2, extensive
cleaning

5. Reassemble the battery in accordance with “ASSEMBLY AND STORAGE”

Removal of Section I – Replacement of Non-Compliant parts

24 – 38 – 51 Page 608
Jul 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
ASSEMBLY AND STORAGE

1. Assembly (refer to IPL, Fig.1)

Note: Tools and equipment are identified in section “SPECIAL TOOLS AND EQUIPMENT”
If necessary, clean the parts to be installed, before any re-assembly. Refer to section:
„CLEANING“

A. In case of battery container , handle, cover replacement always care for correct battery labelling in
contact with Hawker (Refer to “REPAIR” section H)

B. Installation of Connector socket into battery container

I. Place Sealing ring (140) over rear of the connector socket casing (100)
II. Place the four fan disk washers (120) and four countersunk screws (110) into the fixing holes
of the connector socket casing (100)
III. Fix one sealing ring (130) onto each of the four countersunk screws (110)
IV. Place the connector socket (100) with attaching parts (110,120,130,140) into the battery
container (10) and tighten to 2Nm

C. Installation of insulating liners within battery container

I. Insert Bottom liner (170) into the base of the battery container
II. Insert the remaining liners (180 thru 220) into the battery container (10) noting their position
illustrated in the IPL Figure.1.

D. Installation of cells and metallic surface protection

I. Place cells (40) FP23XLM with their polarities in correct position into the battery container (10)
II. Place links (220, 230, 240, 250, 260, 270) and spring washers (60, 160) on cell terminals
III. Torque the hexagonal nuts (50, 150) to 5Nm
IV. Coat the metallic assemblies or parts with Silicone Spray.

Attention: Avoid the coating of the black seals, when using any coating

Note: Silicone Spray is neutral to any polymer part assembled in the battery and it does not
attract dirt, but “excessive use of the spray, cause coated battery components to look
temporarily wet”.

E. Installation of the cover

I. Place the cover (20) in correct position on the battery container (10)
II. Fix the cover (20) with the 4 fastener to the container (10)

24 – 38 – 51 Page 701
Nov 19/13
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
F. Full battery assembly

I. Carry out the steps above A, B, C,D,E consecutively

2. Storage

1. Environmental Storage conditions

Basic requirements recommended for storage rooms:

a) Temperature: Advised average temperature range: 5°C – 35°C.

Temporary deviation in the temperature range of -50°C to +80°C is acceptable during long-
term storage

b) Humidity: 35 – 70% relative humidity.

2. Preparation before storage up to 5 Years in maintained and discharged condition

Note: It is recommended to store batteries in an airworthy condition, either after regular

maintenance or overhaul

 Carry out either the regular maintenance procedure or the Overhaul

 Discharge the battery with 23A to 20V
 Close and tighten the vent plugs of the cells
 Fit the cover in correct position and lock it with the battery container
 Protect the pins of the connector socket with a protective cap against short circuit.
 Always store the battery upright.
 Protect the battery against impact by package, e.g. in the original cardboard box.

3. Storage of batteries operable for service.

Maintained and charged batteries can be stored service-operable for “short-time” limited by storage
conditions

Note: Storage duration of a serviceable battery is directly related to the storage temperature of the
battery.

3.1. Preparation

a. Maintain the battery, as scheduled (either regular Maintenance or General Overhaul)

b. Fit and tighten properly the vent plugs on the cells before closing the battery container
with the cover.

c. Coat the metallic parts with silicone spray and protect the main connector pins from any
short circuit.

24 – 38 – 51 Page 702
Jul 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
d. Store the battery upright.

3.2. Storage Period and intervals for refresh charge

a. Refer to the Storage diagram

b. Subject the battery to refresh charge at the time indicated at the intercept point of
storage temperature and 80% SOC in the diagram below.

c. Two refresh charges after maintenance can be carried out if requirement under 2.3.3 is
met, which results in a maximum of 3 storage periods.

d. If the battery has been subject to three successive periods of short-term storage
periods, it must be subjected to regular maintenance.

24 – 38 – 51 Page 703
Jul 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
3.3 Refresh charge parameter are indicated in table below

Charge current Charge voltage Max Charge time Max charge Current
limitation at close of charge
4.6A 30.1 V 1 hours <4.2A

Limitation for the refresh charged capacity

The recharged capacity during refresh charging must not exceed 4.6 Ah. If, the recharge
capacity exceeds 4.6A, then the battery shall be and subjected to regular maintenance.

3.4 Refresh charge procedure

Note: Don’t carry out any electrolyte level adjustments on cells when applying a Refresh Charge

a. Remove the cover and protective cap from the battery.

b. Connect the battery to the charge / discharge unit
c. Adjust on charger the voltage and the current limitations taken from the table above.
d. Do not remove vent plugs from cells.
e. Charge the cells for the corresponding Max time and record the current versus Time
(Ampere-hour meter).
f. Prior to cut-off charge read and record the battery voltage and charge current.
g. Fit battery cover and protective cap.

3. Packing

The discharged batteries are to be packed in upright position in accordance with national or global
standards for transportation. If available, the undamaged original supplied package of the battery
can be re-used.

4. Transportation

Vented batteries packed in accordance with the instructions are to be transported in upright position.
The package shall be marked with “TOP” and “BOTTOM” and with any information needed for shipment.
CMM, Service bulletins and Log book are to be treated a part of the battery and shall be put into the
transportation package or send separately to same destination.

24 – 38 – 51 Page
Page704
705
Jul20/18
Jul 20/18
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
SPECIAL TOOL, FIXTURES AND EQUIPMENT

1. Special Tools

NOTE: Equivalent substitutes may be used for listed items.

The special tools detailed in the table below are required for Testing / Disassembly /
Assembly / Cleaning / Check / Overhaul and Repair of the F2023XLM battery.

Manufacturers Part
Designation
Number

929 1380 4800 Vent Plug Spanner (Refer to Figure 901)

4611008 Deep Discharge Resistor 1Ω 2 Watt (Refer to Figure 902)

929 1380 459 Cell removal tool (Refer to Figure 903)

Syringe (Refer to Figure 904), Commercial available

Hydrometer: (Refer to Figure 905), Commercial available

2. Materials

Designation
Manufacturers
Specification
Part Number

Commercial Distilled or deionized water. IEC 60993

Available
EN 60993
928 7210 017 Korasilone M
Commercial
Liqui – Moly 3310
Available

24 – 38 – 51 Page 901
Jul 20/18
COMPONENT MAINTENANCE MANUAL
F20/23XLM

Figure 901 – Vent Plug spanner

Figure 902 – Deep Discharge Resistor

24 – 38 – 51 Page 902
JUL 20/18
COMPONENT MAINTENANCE MANUAL
F20/23XLM

Figure 903 – Cell removal tool

(Cell puller)

Figure 904 – Syringe 20ml

24 – 38 – 51 Page 903
Nov 19/13
COMPONENT MAINTENANCE MANUAL
F20/23XLM

Fig. 905 - Hydrometer

24 – 38 – 51 Page 904
Nov 19/13
COMPONENT MAINTENANCE MANUAL
F20/23XLM

ILLUSTRATED PARTS LIST

24 – 38 – 51 TP 1001 Page 1
Nov 19/13
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
INTRODUCTION

1. General

This section provides illustrations and parts breakdown of the F20/23XLM battery, which
can be disassembled, repaired or replaced and reassembled.

2. How to use the Detailed Parts List

The Detailed Parts Lists includes a complete list and figures of the battery components.

It has the following columns:

1st column: Fig. Item – (Figure and item numbers)

2nd column: Part Number – (Manufacturer’s part number)
3rd column: Airline Part Number
4th column: Nomenclature – (List of components)
5th column: Usage Code – (Applicability)
6th column Units per Assembly (Quantity for each immediately higher assembly)

A. Figure and item numbers (Fig. Item)

The figure number for the item given in the list is shown on the first line of each
page.

Each assembly, sub-assembly or item with a part number that is given in the parts
list has an item number. A letter following the item number identifies the variant.
The basic variant is identified with the letter “A”.

Assemblies, sub-assemblies and parts that are not illustrated in the figure are
identifiable with a dash (-) before their item numbers.

B. Manufacturer’s part number (Part Number)

Each assembly, sub-assembly and detail part (that is shown on the figure or not) has
a manufacturer’s part number.

C. List of Components ( Nomenclature)

The list of components is moved to the right to show the relationship between the
parts:

24 – 38 – 51 INTRO 1001 Page 1

Nov 19/13
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
Assembly

. Detail parts for assembly

. Sub-assembly
. Attaching parts and/or storage parts for sub-assembly

. . Detail parts for sub-assembly

. . Sub -sub-assembly
. . Attaching parts and/or storage parts for sub-assembly

. . . Detail parts for Sub-sub-sub-assembly, etc.

A vendor code is given for all items or articles that are not made by the
manufacturer of the assembly.

This vendor code (or the abbreviation “NP”: non procurable) is shown to the right of
the 1st line of the nomenclature.

D. Effectively (Usage Code)

Reference letters (A, B, C etc.) are assigned in the EFF code column to each top
assembly. The reference letter of the applicable top assembly is also shown in the
EFF CODE column for each detail part and subassembly except that no reference
letter is shown for detail parts and subassemblies used on all top assemblies.

E. Quantity Per Assembly

The “Units per Assy.” Column shows the total number of units required per
assembly, per sub-assembly as applicable.

This number can be replaced by the letter REF (Reference) or AR (As Required)

3. Changes

When an item is changed, added or removed, the letter “R” is shown in the right margin (the
date of issue of the page changes).

The letter “R” is shown opposite the page number (in the right margin) when all the number
are changed.

24 – 38 – 51 INTRO 1001 Page 2

Nov 19/13
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
4. Page numbers

The Detailed Parts List is divided into sections. The page numbers are given independently
for each section.

Introduction INTRO 1001 Page 1 to 5

Vendor Code Index VCI 1001 Page 1
Numerical Index, NI/MUN1001 Page 1
Numerical
Detailed Parts List Page 1001
Figure, Main Figure 1 Page 1001-0
Parts List Page 1001-1

24 – 38 – 51 INTRO 1001 Page 3

Nov 19/13
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
VENDOR CODE INDEX

VENDOR CODE NAME - ADDRESS

HAWKER GmbH,
Dieckstrasse 42,
58089 Hagen
D8034 Germany
Tel : +49 (0)23 31 372-0
Fax : +49 (0)23 31 372-183

VCI 1001 Page 1

24 – 38 – 51
Nov 19/13
COMPONENT MAINTENANCE MANUAL
F20/23XLM

24 – 38 – 51
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
NUMERICAL INDEX

UNITS PER
PART NUMBER AIRLINE PART NO. FIG. ITEM
ASSY

1212004 1 50A 80
1212004 1 150A 2
1213933 1 130A 4
1213982 1 80A 40
1214208 1 140A 1
1218186 1 270A 2
1218291 1 240A 5
1218478 1 230A 10
1511219 1 120A 4
1511519 1 60A 40
1511519 1 160A 2
1516396 1 110A 4
2283571 1 70A 40
2287662 1 90A 20
4568996 1 40A 20
4569343 1 30A 1
4572412 1 10A 1
4573547 1 170A 1
4573555 1 220A 2
4573563 1 200A 2
4573571 1 190A 2
4573588 1 180A 5
4573603 1 210A 1
4575134 1 100A 1
4575159 1 260A 3
4575167 1 250A 1
4583794 1 20A 1

IN/NUM 1001 Page 1

24 – 38 – 51 Nov 19/13
COMPONENT MAINTENANCE MANUAL
F20/23XLM

24 – 38 – 51
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

DETAILED PARTS LIST

24 – 38 – 51 Page 1001
Nov 19/13
 COMPONENT MAINTENANCE MANUAL
F20/23XLM

Figure 1 – F20/23XLM Battery, Exploded view

24 – 38 – 51 Page 1001-0
Nov 19/13
 COMPONENT MAINTENANCE MANUAL
F20/23XLM
ILLUSTRATED PARTS LIST

PART NOMENCLATURE EFF. UNITS PER

FIG. ITEM
NUMBER 1234567 CODE ASSY

1 -1 4575126-00 Battery Assembly, F20/23XLM A 1

10A 4572412 . Battery container complete 1
20A 4583794 . Battery cover complete 1
30A 4569343 . . Gasket, cover 1
40A 4568996 . Cell, FP23 XLM complete 20
50A 1212004 . . Hexagonal nut M8 4
60A 1511519 . . Spring Washer B8 2
70A 2283571 . . Spacer 2
80A 1213982 . . Sealing ring 2
90A 2287662 . . Vent plug 1
100A 4575134 . Connector socket complete 1
110A 1516396 . Countersink Screw AM 4x10 4
120A 1511219 . Fan disk V4-3 4
130A 1213933 . Sealing ring 3,3x2,4 4
140A 1214208 . Sealing ring 1
150A 1212004 . Hexagonal nut M8 2
160A 1511519 . Spring Washer B8 2
170A 4573547 . Insulator, bottom 1
180A 4573588 . Insulator 5
190A 4573571 . Insulator 2
200A 4573563 . Insulator 2
210A 4573603 . Insulator 1
220A 4573555 . Insulator 2
230A 1218478 . Connector D5 10
240A 1218291 . Connector D2 5
250A 4575167 . Connector 1
260A 4575159 . Z-Connector 3
270A 1218186 . Connector 2

- DENOTES NOT ILLUSTRATED

24 – 38 – 51 Page 1001-1
Mar 07/16