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DIEHL

COMPONENT MAINTENANCE MANUAL


3214
Diehlluftfahrt Elektronik GmbH

FischbachstraBe 16-20
D-90552 Rothenbach a d Pegnitz
GERMANY
01347

BATTERY
PN 3214-30

COMPONENT MAINTENANCE MANUAL


WITH
ILLUSTRATED PARTS LIST

33-51-07

TP
FEB 04/98

Copyright Diehl Stiftung & Co. 1998


This document is given in confidence and may not be reproduced, stored in a retrieval system
or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or
otherwise, without the prior written permission of Diehl GmbH & Co.

Unless Diehl GmbH & Co. (the company) has accepted a contractual obligation in respect of

the information and data contained herein, such information and data is provided without
responsibility, and the company disclaim all liability arising from its use.

DIEHL
COMPONENT MAINTENANCE MANUAL
3214

RECORD OF REVISIONS

REVISION NO.

ISSUE DATE

INSERTED

-------------...- -----------
DATE

BY

OCT 15/84

INSERTED

OLE

OCT 15/86

INSERTED

OLE

MAY 31/89

INSERTED

OLE

JUN 20/97

INSERTED

OLE

FEB04/98

INSERTED

OLE

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ROR

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DIEHL
COMPONENT MAINTENANCE MANUAL
3214

RECORD OF TEMPORARY REVISIONS

TEMPORARY
REVISION NO.

PAGE
NUMBER

ISSUE
DATE

INSERTED

REMOVED

------ --- ------- -----DATE

BY

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DATE

BY

ROTR
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DIEHL
COMPONENT MAINTENANCE MANUAL

3214
SERVICE BULLETIN LIST

INSERTED
SB NO.

ISSUE DATE

----..-----------...-..- ----- ----------


DATE

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BY

SBL

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DIEHL
COMPONENT MAINTENANCE MANUAL

3214

LIST OF EFFECTIVE PAGES

SUBJECT

PAGE

DATE

TITLE PAGE (TP)

FEB 04198

RECORD OF REVISIONS
(ROR)

JUN 20/97

RECORD OF TEMPORARY
REVISIONS (ROTR)

JUN 20/97

SERVICE BULLETIN
LIST (SBL)

JUN 20/97

LIST OF EFFECTIVE
PAGES (LEP)

FEB 04/98

LIST OF MATERIALS
(LOM)

JUN 20197

TABLE OF CONTENTS
(TOC)

JUN 20/97

INTRODUCTION
(INTRO)

1
2

JUN 20/97
JUN 20/97

DESCRIPTION AND
OPERATION

1
2
3
4
5
6

JUN 20197
JUN 20/97
JUN 20/97
JUN 20/97
JUN 20/97
BLANK

TESTING AND
FAULT ISOLATION

101
102
103
104
105
106
107
108
109
110

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FEB 04198
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PAGE

SUBJECT

DATE

DISASSEMBLY

301
302

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JUN 20/97

CLEANING

401
402

JUN 20/97
BLANK

CHECK

501
502

JUN 20/97
BLANK

REPAIR

601
602

JUN 20/97
JUN 20/97

ASSEMBLY
(INCLUDING
STORAGE)

701
702

JUN 20/97
JUN 20/97

SPECIAL TOOLS,
FIXTURES, AND
EQUIPMENT

901
902

JUN 20/97
BLANK

IPL1001
INTR01001-1
INTR01001-2
INTR01001-3
INTR01001-4
EDI1001-1
Nl1001-1
Nl1001-2

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JUN 20/97
JUN 20/97
JUN 20/97
JUN 20/97

DPL1001
1001-0
1001-1
1001-2

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JUN 20/97
BLANK

ILLUSTRATED
PARTS
LIST

DETAILED
PARTS LIST

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DIEHL
COMPONENT MAINTENANCE MANUAL

3214
INTRODUCTION

1.

2.

General
A.

This manual has been written in accordance with the requirements set out in the specification A TA 100

B.

The manual gives the maintenance and repair instructions of the battery.

Manufacturer
The battery is manufactured by:

Diehl Luftfahrt
Elektronik GmbH
Fischbachstr. 16-20

FSCM: 01347

3.

Layout of the Manual


A.

This manual contains

technical data,
description and operation,
instructions for maintenance,
data for testing and repair

of the battery.

B.

4.

Data and figures of the parts of the battery are contained in the Illustrated Parts Ust
(IPL).

Shop Verification
The procedures described in this manual are workshop-verified.

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COMPONENT MAINTENANCE MANUAL

3214
5.

Warnings. Cautions. Notes


A.

WARNING
Warnings call attention to use of materials, processes, methods, procedures or limits
which must be precisely adhered to in order to avoid injury or death of persons.

B.

CAUTION
Cautions call attention to use of materials, processes, methods, procedures or limits
which must be precisely adhered to in order to avoid damage of equipment.

C.

NOTE
Notes call attention to methods which make the job easier.

6.

Abbreviations
The abbreviations used in the descriptive portion of this manual are listed below:
ATA ... .. .. .. .. .. .
e.g................
Fig ................
in ..................
max......... .....
INTRO .. ... .. . . .
IPL .. ...... .. .. ...
lb..................
LEP . .. .. .. ... .. ..
LOM ... .. .. .. .. ..
NiCd .... .. .. .. ...
No ................
PN . .. .. .. .. . .. .. . .
Ref. .. ...... . . ... .
ROR .. ... .. .. .. ..
ROTR .. . .. ... . ..

7.

Air Transport Association of America


exempli gratia (Latin), for example
figure
inch(es)
maximum
introduction
illustrated parts list
pound
list of effective pages
list of materials
nickel/cadmium
number
part number
reference
record of revisions
record of temporary revisions

Vendor Codes
Codes, names and addresses of vendors used in the maintenance and repair instructions
are listed below:
CODE

NAME

ADDRESS

02650

WACKER-CHEMIE GmbH

Hans-Seidel-Platz 4
0-81737 Munchen

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COMPONENT MAINTENANCE MANUAL

3214
DESCRIPTION AND OPERATION

1.

General
The battery (Ref. Fig. 1) is a part of the aircraft supply units, e.g. for emergency lighting. In
case of a breakdown of the aircraft power supply the battery supplies electrical circuits with
its stored energy for a defined time period.

ROTATED 180

BATTERY
Figure 1

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COMPONENT MAINTENANCE MANUAL
3214

9
1
2
3
4
5
6

Captive screw
Cover
Battery contact(-)
Captive screw
Connector
Battery contact(+)

8
7
8
9
10
11
12

Case
Insulator assy
Welding lug
Insulation disc
NiCd cell
Heating mat

BATTERY- CUTAWAY VIEW


Figure 2

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COMPONENT MAINTENANCE MANUAL

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2.

3.

Description (Ref. Fig. 2)

A.

The battery consists of 5 NiCd cells (11) connected in series. Welding lugs (9) are the
connection between the individual cells. An insulating disk (1 0) around the positive
pole of each cell is the protection against short circuits. The positive (+) tenninal (6)
and the negative (-) tenninal (3) of the battery are high current female contacts.

B.

The battery block assembly consists of the five connected cells and the insulator assy
{8) inside them .
The elastic and heat-conductive material of the insulator assy helps to suppress vibrational movements of the cells.

C.

The battery block assembly is installed in a housing which consists of a case (7) and a
cover (2). Three captive screws (4) connect both parts together.
Recesses in the case and in the cover hold the battery block assy in place.

D.

A heating mat (12) is glued into the case (7) and encloses the cells. A temperature
sensor and a thermostat which is embedded in the insulator assembly monitor the
temperature of the battery.

Operation (Ref. Fig. 3)


A.

The temperature at which the battery is discharged has a pronounced effect on its
service and voltage characteristics. This is due to the reduction in chemical activity and
the increase in battery internal resistance at lower temperatures.
The best performance is obtained at an operation temperature between 20C [68F]
and 40C [104F].
At higher temperatures the chemical deterioration may be rapid enough during discharge to cause a loss in capacity.

B.

At low ambient temperatures the heating mat {R1) allows to maintain the battery temperature in the required range for best service.
The NTC resistor R2 is the sensor for the temperature regulating circuit which is a part
of the connected supply unit.
The thermostat S1 opens the heating current circuit at approximately 50C (122F] in
case of a malfunction of the regulating circuit.
The resistor R3 in parallel to the thermostat S1 is only for test purposes of the heating
circuit.

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COMPONENT MAINTENANCE MANUAL

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4.

5.

Technical Data

Battery type

Nickel-cadmium

Nominal voltage

6V

Capacity

4Ah

Number of cells

Heating mat

370/20W

Temperature sensor
Type
Resistance at 25C [77F]

NTC resistor
12 kO

Thennostat
Function
Set point

opens
50C 5C [122F

Operating temperature

-15C to +40C [+5F to +104F]

Storage temperature

-40C to +50C [-40F to +122F]

Dimensions

115 X 80

Mass (weight)

1.1 kg [2.4 lb.)

9F]

65 mm [4.5 X 3.1

2.6 in.)

Modification Statuses
There are batteries with modification statuses A and B in operation. As both types are
fully interchangeable, it is not necessary to modify units to the higher status.
Figures 3 and 4 show the difference between modifications A and B: an additional connection between contact 2 and resistor R1 . It is realized as a land on the connector (see
Fig. 4). It was necessary to incorporate this connection to improve the tests with automatic test equipment performed during manufacturing.

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COMPONENT MAINTENANCE MANUAL

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CONNECTOR

( ONNECTOR

CIRCUIT DIAGRAM
Figure 3

Modification A

Modification 8

~ ~ ~ ~ ~.----.6
:,

CONNECTOR
Figure 4

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3214
TESTING AND FAULT ISOLATION
1.

Test Equipment
Table 101 shows the necessary test equipment for the battery test procedure.
NOTE: Equivalent substitutes may be used.
QTY

TYPE

RANGE

SOURCE

DC power supply

0 ... 10V,
current limitation adjustable 0.5 A,
reverse polarity protection

commercial

Load resistor

0.88 n 2%, sow.


resistance of connecting leads
included

commercial

Digital multimeter (DMM)

Ri ~ 10 kn/V,
4 ... 8 VDC,
20 ... 40 n. s ... 25 kn,
@ measuring current of ~ 1 mA

commercial

Megohm meter

500 VDC, 0 ... 100 Mn

commercial

Climatic chamber

Temperature adjustable
600C [140F]

commercial

Stop watch

Elapsed time 30 minutes

commercial

Contact pin

Flatbed recorder

see Fig. 101


Selectable chart speed,
input impedance ~ 1 Mn,
voltage range 10 V

commercial

TEST EQUIPMENT
Table 101

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COMPONENT MAINTENANCE MANUAL
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2.

Special Tools
Figure 101 shows the tool necessary for the battery test procedure (2 pins required) .

Material: copperbrass

- 1 mm [0.04 in.)

8.5 0.2 mm [0.33 0.1 in.}

CONNECTING PIN
Figure 101

3.

Test Conditions
The necessary environmental conditions for the test procedure are:
Ambient temperature ................................................................. 10C to 30C [50F to 86FJ
Relative humidity ... ... . .......... ... ............. .. .. .. .. .... . ... . .. .. .. .. . .. .. .. .... .. .... .. .... . .. ... .... .. less than 80%
Atmospheric pressure .. .. . . .. . .. .. .. . .. . .. . .. .. .. .. .. .. . .. .. .. .. . .. .. . .. . .. ... . .. . .. . .. . . .. .. . .. .. . .. . .. .. . local standard

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COMPONENT MAINTENANCE MANUAL
3214

4.

Test Procedure
A.

B.

C.

Visual Check
(1)

Examine the battery for mechanical damage.

(2)

Make sure that the 3 screws which attach the cover to the case are tight.

(3)

Make sure that there are no leads squeezed between cover and case.

Insulation Resistance
(1)

Connect the negative terminal of the megohmmeter to the negative battery terminal(-) and the positive terminal to contact no. 1 of the connector.

(2)

Set the test voltage to 500 V DC.


Make sure that the insulation resistance is equal to or more than 10 Mn.

(3)

Set the test voltage to 0 V.


Remove the megohmmeter terminal from contact no. 1 and connect it to contact
no. 3 of the connector.

(4)

Set the test voltage to 500 V DC.


Make sure that the insulation resistance is equal to or more than 10 Mn.

(5)

Set the test voltage to 0 V.


Remove the megohmmeter terminal from the negative battery terminal and connect it to contact no. 1 of the connector.

(6)

Set the test voltage to 500 V DC.


Make sure that the insulation resistance is equal to or more than 10 Mn.

(7)

Set the test voltage to 0 V.


Remove the battery from the megohmmeter.

Functional Test
(1)

General
Make sure that the battery temperature is stable between 18C and 28C [64F
and 82F].
CAUTION:

USE ONLY PINS AS SHOWN IN FIGURE 101 TO CONNECT A TEST


CIRCUITRY TO THE NEGATIVE AND POSITIVE TERMINAL OF THE
BATTERY.

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COMPONENT MAINTENANCE MANUAL
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(2)

Discharge
(a)

Set the DMM to measure the DC voltage.

(b)

Refer to figure 102 and connect the discharge circuitry to the battery as
shown.
CAUTION:

CAUTION:

DO NOT ALLOW THE BATTERY VOLTAGE TO DECREASE TO


LESS THAN 5 VOLTS. THE POLARITY OF THE CELLS CAN BE
REVERSED.
A DISCHARGE VOLTAGE OF 4.5 VOLTS OR LESS WILL DES-

TROY THE CELLS IMMEDIATELY.

DISCHARGE CIRCUITRY
Figure 102

(c)

Set the test equipment switch to ON.


Discharge the battery into the load until the meter shows a voltage
between 5 V and 5.3 V.

(d)

Set the test equipment switch to OFF and disconnect the discharge circuitry from the battery.

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COMPONENT MAINTENANCE MANUAL

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(3)

(4)

Charge
(a)

Set the output voltage of the DC supply to 10 V 1 V and the short circuit
limitation to a current of 450 mA 20 rnA.

(b)

Obey the polarity and connect the DC supply to the battery tenninals.

(c)

Switch on the DC supply and charge the battery for 14 hours.

(d)

Switch off the DC supply and remove it from the battery.

Test of Several Circuits (Ref. Fig. 103)

(33.3 n to 40.7 n)

TEST CIRCUITRY
Figure 103
(a)

Set the DMM to measure the DC voltage.


Connect the DMM to the negative terminal(-) of the battery and to contact
no. 6 of the connector.
Make sure that the value of the voltage is more than 5.6 V.
Disconnect the DMM from the battery.

(b)

Set the DMM to measure the resistance.


Connect the DMM to contact no. 1 and no. 4 of the connector.
Make sure that the value of the resistance is between 33.3 n and 40.7 n.
Disconnect the DMM from the battery.

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(c)

(5)

Set the DMM to measure the resistance.


Connect the DMM to contact no. 3 and no. 5 of the connector.
Make sure that the value of the resistance is between 5 kn and 25 kn.
Disconnect the DMM from the battery.

Capacity Test
(a)

General
In the following procedure you make a check of the capacity. This test
includes the measurement of the amount of the self-discharge rate and the
detection of batteries with the memory effect.
NOTE:

(b)

Begin the capacity test within 24 hours after the charge cycle.

Procedure
1

Set the DMM to measure the DC voltage.

Refer to figure 104 and connect the test circuitry to the battery as
shown.

CAUTION:

A DECREASE OF THE BATTERY VOLTAGE UNDER LOAD TO


LESS THAN 5.0 VOLTS MAY CAUSE A CELL REVERSAL.
A DISCHARGE VOLTAGE OF LESS THAN 4.5 VOLTS WILL
DESTROY THE CELLS IMMEDIATELY.

TEST CIRCUITRY- CAPACITY TEST


Figure 104

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3214

Do the following:
Start the flatbed reCQrder.
Set the switch of the test circuitry to ON in order to start the discharge operation, and at the same time start the stop watch to
measure the elapsed time.
Look at the voltmeter and make sure that the voltage at the beginning of the discharge is equal to or more than 6 V.

Measure the voltage of the battery.


Make sure that the shown value is not less than 5.6 V.

When 15 minutes have elapsed:

deleted

Set the test circuitry switch to OFF when the battery voltage reaches
5.0V.

g
Ill

DISCHARGE CURVE WITHOUT MEMORY EFFECT


~ ..........

--'

<JSta1

5.0

~
...
Ti me

!!
0
>

DISCHARGE CURVE WITH MEMORY EFFECT

- .....__
<J5tart

5.0

1"?2. Stage

.......

~
Ti me

DISCHARGE CURVE UNDER LOAD


Figure 105

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(6)

Refer to figure 105 and examine the plotted discharge curve.


Make sure that the curve does not show the memory effect (second
discharge stage).

Test of the Thennostat


CAUTION:

IN THE FOLLOWING TEST EXTREMELY HIGH TEMPERATURES


WILL STRESS THE BATTERY. IT IS RECOMMENDED TO DO THIS
TEST ONLY IF THERE IS THE SUBSTANTIAL SUSPICION OF A DEFECTIVE THERMOSTAT.

(a)

Put the battery into the climatic chamber.

(b)

Increase the temperature of the chamber to 60C [140F) within 30 minutes


an hold the temperature for a period of 90 minutes.

(c)

Set the DMM to measure the resistance.

(d)

Remove the battery from the climatic chamber and connect the DMM to the
contacts no. 1 and no. 4.

(e)

Make sure that the value of the resistance is between 3.3 kn and
3.374 kn.

(f)

Disconnect the DMM from the battery and store the battery at an ambient
temperature of 150C to 200C [59F to 68F) for at least 2 hours.

(g)

Repeat step 4.C.(4)(b).

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5.

Fault Isolation

A.

B.

General
(1)

This section provides the fault isolation information for the battery.

(2)

Examine the external wiring and serviceability of the test circuitry components
first before you begin to dismantle the unit.

Fault Isolation Chart


FAULT
Insulation resistance out
of order

CORRECTION

PROBABLE CAUSE

Examine heating mat and


replace it if necessary

Short circuit between


heating mat, battery block
and/or other circuits

Examine wiring and repair


it if necessary
Examine connector and
replace it if necessary

Connector faulty
Resistance of heating mat
circuit out of tolerance

Connection between wiring Examine wiring and conand connector defective


nector; replace connector.
if necessary
Heating mat faulty

Resistance of temperature sensor circuit out of


tolerance

Examine heating mat and


replace it if necessary

Connection between wiring Examine wiring and conand connector defective


nector; replace connector
if necessary
Temperature sensor defective

Replace battery block

Terminal voltage out of


tolerance during capacity
test

Capacity too low, or battery Recondition battery,


block defective
refer to paragraph C.

Battery shows memory


effect

Decrease of capacity

Recondition battery,
refer to paragraph C.

Self-discharge rate too


high

Battery pack defective

Recondition battery,
refer to paragraph C.

Fails test of thermostat

Thermostat defective

Replace battery pack

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C.

Reconditioning of the Battery


CAUTION:

DO THE FOLLOWING STEPS ONLY WITH AN ASSEMBLED BATTERY.


USE ONLY PINS AS SHOWN IN FIGURE 101 TO CONNECT A TEST CIRCUITRY TO THE POSITIVE AND NEGATIVE TERMINAL OF THE BATTERY.

(1)

Refer to section 4.C.(2) and discharge the battery.

(2)

Refer to section 4.C.(3) and charge the battery.

(3)

Refer to section 4.C.(2) and discharge the battery.

(4)

Refer to section 4.C.(3) and charge the battery.

(5)

Refer to section 4.C.(5) and repeat the capacity test.

(6)

In case the battery does not show a noticeable improvement and does not fulfill
the requirements, replace the battery pack.

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DISASSEMBLY
1.

Special Tools. Fixtures. and Equipment


Figure 301 shows the special tool required for disassembly of the battery.

Handle

25 ( 1 1

N
N

19[0.75)

a;'
.-

Dimensions: mm (inch)

Material: carbon tool


steel, type\.11

Detail X
Scale 2:1
EXTRACTION TOOL
Figure 301
2.

Procedure (Ref. IPL Fig. 1)


A.

General
WARNING:

A BAITERY MAY CAUSE INJURY TO PERSONNEL AND DAMAGE TO


PARTS WHEN THE BATTERY TERMINALS COLLIDE TOGETHER.
IN CASE OF A DEFECTIVE BATTERY PACK WHICH WILL BE SCRAPPED,
THE BATTERY MUST BE TOTALLY DISCHARGED BEFORE DISASSEMBLY.

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CAUTION:

B.

C.

THE BATTERY PACK IS NOT REPAIRABLE.


IT CONTAINS THE POLLUTANT CADMIUM.
FOR SCRAP DISPOSAL OBEY THE LOCAL LEGAL REGULATIONS.

(1)

Refer to TESTING AND FAULT ISOLATION, 4.C.(2), and connect the battery to
the discharge circuitry.

(2)

Discharge the battery into the load until the voltage is


5.1 V, in case you will keep the battery pack for re-usage,
less than 1 V, in case you will scrap the battery block.

(3)

Remove the test circuitry from the battery.

Removal of the Cover (10)


(1)

Unscrew the 3 captive screws (20).

(2)

Move apart the cover.

Battery Block
(1)

Remove the cover (10).

(2)

Remove the contacts (110), using the extraction tool.


CAUTION:

IN CASE THE BATTERY PACK IS NOT COMPLETELY DISCHARGED


AND KEPT FOR RE-USAGE, ISOLATE THE CONTACTS WITH SELFADHESIVE TAPE TO PREVENT UNWANTED CONNECTIONS DURING HANDLING.

(3)

Pull connector (160) carefully out of the recess in the case (140).

(4)

Remove the cable spot tie.

(5)

Desolder the cable connections of the connector.

(6)

Remove the connector and keep it.

(7)

Pull the battery block (40) out of the case (140).

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CLEANING
1.

Materials
Use the cleaning material shown in Table 401 to clean the battery and its parts.
NOTE: Approved alternatives may be used for listed items.
ITEM
Cleaning fluid

IDENTIFICATION

SOURCE

Isopropyl alcohol

Local Purchase

Cleaning Materials
Table 401
2.

Procedure
WARNING :

DO NOT GET CLEANING FLUID ON YOUR SKIN, IN YOUR EYES, OR NEAR A


FLAME. USE ONLY IN AN AREA WITH A GOOD FLOW OF AIR.

A.

Special instructions are not required.

B.

Use standard industry practices to clean the battery.

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CHECK

Check all parts for obvious defects in accordance with standard industry practices.

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REPAIR
1.

Materials. Tools. Fixtures. and Equipment


A.

The materials used in these repair procedures are given in Table 601.
NOTE:

Equivalent substitutes may be used for listed items


ITEM

SOURCE

IDENTIFICATION

Cleaning fluid

Isopropyl alcohol

Local purchase

Silicone adhesive

Elastosil E43

02650

Lacing cord, nylon

MIL-T-43435

Local purchase

Protective varnish for


PC boards

Polyurethane varnish

Local purchase

Material for Repair


Table 601
B.
2.

No special tools, fixtures, and equipment are required for the repair of the battery.

Replacement of the Heating Mat (Ref. IPL Fig. 1)


A.

Refer to chapter DISASSEMBLY and dismantle the battery.

B.

Remove the heating mat (130) from the inner side of the case (140).

C.

Remove still adherent residues on the side wall with mechanical means.

D.

Hand clean inner side wall with cleaning fluid and a lint-free cloth.

E.

Put silicone adhesive on the inner side wall of the case and attach the replacement
heating mat carefully.

F.

Before installation of the battery block allow the adhesive to cure for at least 24 hours
at room temperature.

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3.

Replacement of the Battery Pack (Ref. IPL Fig. 1)


A.

Refer to chapter DISASSEMBLY and dismantle the battery.

B.

Install the replacement battery pack (40) in the case (140).

C.

Push the contacts (110) into their bores in the case.


Make sure that the contacts are locked.

D.

Refer to figure 601.


Install the end-fitted wires to the connector and solder them in position.

E.

Clean the soldering joints with cleaning fluid.

F.

Apply protective varnish on the soldering joints and allow varnish to dry for 4 hours.

G.

Secure the wire leads with a lacing spot tie near the connector.

REO

+
CONNECTOR

WIRIN G DIAGRAM
Figure 601

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COMPONENT MAINTENANCE MANUAL

3214

ASSEMBLY (INCLUDING STORAGE)

1.

Materials
No materials, tools or fiXtures are required for assembly.

2.

Procedure (Ref. IPL Fig. 1)


A.

Install the connector (160) in the recess of the case (140).

B.

Position the cable leads next to the cells in order to prevent squeezing between case
and cover.

C.

Put the cover (10) on the assembly. Make sure that no leads are squeezed.

D.

Attach the cover with the 3 captive screws (20) and washers (30).

E.

Refer to figure 701 and measure the protruding thread of each attaching screw (180).
If necessary, adjust dimension A by inserting or removing the washer (190) and/or the
washer (200).

Dimension A :
5 .5 mm

[ 0.217 in.

~ A ~

6.0mm

0.236 in. ]

ATTACHING SCREWS
Figure 701

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COMPONENT MAINTENANCE MANUAL
3214
3.

Storage (immediate serviceability not required)


NOTE:

It is not necessary to charge the battery before storage.

A.

Prepare and store the battery in accordance with the standard industry practices.

B.

The ambient conditions for storage are:


Temperature .................................................................................... -40C ... +50C
(-40F ... +122F]
with an annual average of ............................................................... +10C ... +25C
[+50F ... +77F]
Relative humidity .. ... .. .... .... ... .. . .. .... . ...... ... . .. ... . .. .. .. . ......... annual average 60% max.

4.

Storage (immediate serviceability is required)


A.

B.

Storage under Trickle Charge


(1)

Discharge and charge the battery in accordance with TESTING AND FAULT
ISOLATION, 4.C.(2) and (3).

(2)

Store the battery under workshop environmental conditions and connected to a


constant current source with a charge current of 90 mA to 11 0 mA.

(3)

Remove the battery from the constant current source after 6 months and do a
functional test in accordance with TESTING AND FAULT ISOLATION, 4.C.(2)
thru 4.C.(5).

Storage without Trickle Charge


NOTE:

Seeing that the self-discharge rate proceeds at a lower rate at reduced temperatures, refrigerated storage is recommended.

(1)

Discharge and charge the battery in accordance with TESTING AND FAULT
ISOLATION, 4.C.(2) and (3).

(2)

Store the battery at a temperature of approx. 0C [+32F]. The loss of capacity


will be 10% to 15% within 2 months.

NOTE:
(3)

Warm the refrigerated battery before discharge to get maximum capacity.

After 12 months do a functional test in accordance with TESTING AND FAULT


ISOLATION, 4.C.(2) thru 4.C.(5).

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COMPONENT MAINTENANCE MANUAL
3214

SPECIAL TOOLS. FIXTURES, AND EQUIPMENT

1.

2.

General
A.

Perform the work in a clean workshop environment.

B.

Perform the work under normal ambient conditions, i.e.

room temperature ............................................................................. +10C ... +30C


[+50F ... +86F)

atmospheric pressure .. ... .. .. .. .. .. .. ... .. . ... .. . ... .. . .. .. .. .. .. . .. .. .. . ... .. . .. .. .. .. . .. ... local standard

relative humidity.................................................................................. less than 80o/o

Special Tools. Fixtures. and Equipment List


NOTE:

Equivalent substitutes may be used for listed items.

NOMENCLATURE
DC power supply

APPLICATION

SPECIFICATION

SOURCE

o V...10 V; current limitation

commercial

Charge of battery

0.88 0 2%, 50 W;
resistance of connecting
leads included

commercial

Discharge of battery

SOOVDC,

commercial

Insulation resistance
measurement

adjustable 0.5 A; reverse


polarity protection
Load resistor

Megohmmeter

o Mn thru 1oo Mn

Climatic chamber

600 c [1400F]

commercial

Test of thermostat

Stop watch

30 min. elapsed time

commercial

Functional test

see Fig. 101

Functional test

commercial

Functional test

see Fig. 301

Disassembly

Contact pin
Flatbed recorder
Extraction tool

10 V voltage range

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COMPONENT MAINTENANCE MANUAL
3214

ILLUSTRATED PARTS LIST

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COMPONENT MAINTENANCE MANUAL
3214

INTRODUCTION

1.

General
This ILLUSTRATED PARTS LIST (IPL) contains the complete listing of all replaceable parts
of the BATTERY.

2.

Material Arrangement
This IPL comprises the following sections:
A.

Introduction
The introduction contains all explanatory information for the individual sections as is
necessary for use of the IPL. The introduction further contains a list of abbreviations
used in the detailed parts list, as well as a list of manufacturers' codes together with
manufacturers' names and addresses.

B.

Equipment Designator Index


The Equipment Designator Index is an alpha-numerical listing of equipment designators assigned to items of the electrical and electronic equipment; it provides a crossreference to the figure/item number.

C.

Numerical Index
This section contains a listing of part numbers of all items listed in the detailed parts
Jist in alpha-numerical sequence, with cross-reference to respective Fig./ltem Nos. as
well as units per assy.
The order of precedence in beginning the part number arranoement at the extreme
left-hand (first) position is as follows:
letters A through Z (except 0 to be considered as zero),
numerals 0 to 9.
For subsequent rows the order is:
a dash,
letters A through Z (except 0 to be considered as zero}
numerals 0 to 9.

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COMPONENT MAINTENANCE MANUAL
3214

D.

Detailed Parts List


(1)

Column FIG./ITEM
The first number in the first line of a page indicates the number of the figure
illustrating the part. The second number indicates the item number by which the
part is identified on the illustration. A dash placed before the item number indicates that the part is not illustrated.

(2)

Column PART NUMBER


The part number column contains the original manufacturer's part number. If
standard part numbers are used, the standard part number is listed in this
column.

(3)

Column AIRLINE PART NO.


This column is left blank for airline internal use.

(4)

Column NOMENCLATURE
(a)

Indenture System
The indenture system used in the Detailed Parts List shows the relationship between parts and assemblies and the next higher assemblies as follows:

1234567
Assembly
Attaching Parts for Assembly
Detail Parts for Assembly
Sub-Assembly
Attaching Parts for Sub-Assembly
Detail Parts for Sub-Assembly
Sub-Sub Assembly
Attaching Parts for Sub-Sub Assembly
Detail Parts for Sub-Sub Assembly
(b)

Attaching Parts
The Attaching Parts are shown directly after the assembly or a part thereof.
They are listed under the same indenture number as the item they attach,
they are preceded by the words "Attaching Parts" and are followed by
three asterisks.

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COMPONENT MAINTENANCE MANUAL
3214

(c)

Vendor Code
Parts manufactured by companies other than DIEHL are identified by an
appropriate vendor code following the nomendature. Vendor codes are in
accordance with current issues of Federal Supply Codes for Manufacturer's Handbook H4-1 , H4-2 and H4-3, and are preceded by the letter 'V'.
Standard parts such as AN , DIN, MS, etc. are not identified by a vendor
code.

(5)

Column EFF CODE


Part variations concerning a certain equipment group are indicated by a letter (A,
B, C etc.). Absence of a code indicates that a part applies to all models.

(6)

Column UNITS PER ASSY


This column contains the quantity of a specific catalog-sequence-numbered part
required in the built sequence of only one (if more than one exists), next higher
sub-sub assembly, sub-assembly, assembly, or installation level as applicable.
For bulk items, the letters 'AR' are inserted in the quantity column to indicate 'as
required'. When items are listed for reference purposes, the letters 'RF' are inserted.

3.

How to use the Illustrated Parts List


A.

B.

The part number is known


(1)

Find the part number in the numerical index. Note figure and item number.

(2)

Tum to figure.

(3)

Locate the part on the illustration and in the parts list by means of item number.

The part number is unknown


(1)

Refer to figure 1 and look for title of figure in which the part should be shown.

(2)

Note the figure number.

(3)

Tum to the illustration and find the part.

(4)

Refer to the corresponding item number in the list.

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COMPONENT MAINTENANCE MANUAL
3214

4.

List of Abbreviations
The following abbreviations have been used in this IPL:
DET ...................
EFF ...................
HEX..................
IPL ....................
K .......................
PN .....................
RF .....................
REQ ..................
SUPSD .............
SUPSDS ...........
TTL ...................

5.

DETAIL
EFFECTIVE/EFFECTIVITY
HEXAGON
ILLUSTRATED PARTS LIST
KILO
PART NUMBER
REFERENCE
REQUIRED
SUPERSEDED
SUPERSEDES
TOTAL

List of Vendors
FSCM

VENDORNAMEANDADDRESS

D0140

Roederstein GmbH
Schillerstr. 2
D-84034 Landshut

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COMPONENT MAINTENANCE MANUAL

3214
EQUIPMENT DESIGN ATOR INDEX

EQUIPMENT
DESIGNATOR

FIG.
ITEM

P1

1 -160

R3

1 -150

EQUIPMENT
DESIGNATOR

FIG.
ITEM

EQUIPMENT
DESIGNATOR

33-51-07

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ITEM

EOI 1001-1
JUN 20/97

DIEHL
COMPONENT MAINTENANCE MANUAL

3214

NUMERICAL INDEX

PART NUMBER

AIRLINE PART NO.

FIG.

ITEM

TTL
REQ

1
1

-30A
200

3
4

150

R DIN125-3-2NRST
R

DELETED
R DIN125A3-2NRST
DIN12585-3NRST
MK3-3-3KPM1 PC

R TESA118-12MM
DELETED
R
R TX16-1929BLUE
DELETED
R
TX16-1929RED
R
R
DELETED
R TX24-1936RED
DELETED
R

1
1

3214-30

1
-1A

RF
RF

R 773-318-04
DELETED
R

R
R
R
R

774-003-90
774-026-56
774-026-70
DELETED
774-026-71
DELETED
774-026-85
774-026-86
774-026-87
774-026-88

AR
1

1
1

190
10

1
1

160
-160A

1
1

1
1
1

180
20
170

4
3
1

- Item not illustrated

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DIEHL
COMPONENT MAINTENANCE MANUAL
3214

PART NUMBER

AIRLINE PART NO.

FIG.

ITEM

TTL
REQ

774-034-44
R 774-034-71
R
DELETED
R 774-034-80
R
DELETED
n4-043-50
774-043-66
774-066-90

40

1
1
1

140
130
-240

1
1
1

110

779-023-66
SEE MK3-3-3KPM1 PC

R 779-226-09
R
DELETED
779-413-55
779-585-30
SEE DIN12585-3NRST
779-585-98
SEE DIN125A3-2NRST

- Item not illustrated

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COMPONENT MAINTENANCE MANUAL
3214

DETAILED PARTS LIST

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JUN 20/97

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COMPONENT MAINTENANCE MANUAL

3214

BATIERY
IPL Figure 1

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JUN 20/97

DIEHL
COMPONENT MAINTENANCE MANUAL

3214

FIG./
ITEM

-1

PART NUMBER

3214-30

-1 A 3214-30
10

R
R

774-026-56

20
7 74-026-87
30
DIN125-3-2NRST
-30A DIN125A3-2NRST

R
R
R
R

R
R

40
50
60
70
80
90
100
110
-120
130
140
150

160

774-034-44
779-226-09
774-034-80
774-026-70
774-034-71
TESA118-12MM
774-026-71
779-413-55
773-318-04
774-043-66
774-043-50
MK3-3-3KPM1 PC

774-026-85

-160A 774-026-85
170

180
190
200

R
R

210
220
230
-240

774-026-88
774-026-86
774-003-90
DIN125B5-3NRST
TX1 6-1929RED
TX1 6-1929BLUE
TX24-1936RED
774-066-90

AIRLINE
PART
NUMBER

NOMENCLATURE

1234567
BATTERY, MODA
SUPSD BY ITEM 1A
BATTERY, MOD B
SUPSDS ITEM 1
.COVER
ATTACHING PARTS
. SCREW, SPECIAL, M3
DELETED
WASHER, FLAT
DIEHL PN 779-585-98

UNITS
PER
CODE
ASSY
EFF

RF

RF
1
3
3

***

.BATTERY BLOCK ASSY


DELETED
DELETED
DELETED
DELETED
DELETED
DELETED
CONTACT
DELETED
.MAT, HEATING
.CASE
(VD0140)
. RESISTOR
3.3 Kn :t 1 %
DIEHL PN 779-023-66
CONNECTOR, MOD A
SUPSO BY ITEM 160A
. CONNECTOR, MOD B
SUPSDS ITEM 160
PLATE, IDENTIFICATION
SCREW, CAPTIVE, M5
WASHER, FLAT
WASHER, FLAT
DIEHL PN 779-585-30
DELETED
DELETED
DELETED
.LABEL

2
1
1
1

1
1
4
AR
4

Dash (-}item not illustrated

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