Model 650 Maintenance Manual (Rev 38)

33-50-00 (Rev 30)

EMERGENCY LIGHTING - ADJUSTMENT/TEST

1. General
A. This section is concerned with operational and circuitry tests of emergency lighting battery pack(s) capacity test, and charging
the battery pack(s).
B. For emergency lighting battery pack circuit testing, charging, and capacity testing, the Lee Air battery pack testers (76345-1
and -2) and the Aero Mach battery pack tester (CJMD333-001) are available. The Lee Air battery pack tester (76345-1) has
built-in volt and ammeters. The Lee Air (76345-2) and Aero Mach (CJMD333-001) battery pack testers requires the use of
external digital voltmeters. When you use tester (76345-1), 28.5 VDC external power source is connected to the tester in order
to provide power for the internal voltmeter and ammeter.
C. Charging the emergency lighting battery packs is done herein with use of the above Lee Air tester (76345-1), a Lee Air battery
pack charger (76354-1), an Aero Mach (CJMD333-001) battery pack tester/charger or a locally fabricated charger. Refer to
Lighting - General, Tools and Equipment, for the testers/charger utilized. Refer to Figure 501 for electrical schematic of locally
fabricated battery charger.
TASK 33-50-00-710
2. Emergency Lighting System Operational Check
NOTE: The emergency lighting battery packs need installed to do this test. Emergency lighting to be tested
includes the passenger lights, exit sign lights, exterior emergency lights, and one over-the- wing escape
route light.
A. Emergency Lighting System Operational Check
(1) With no electrical power on the airplane, the DC POWER BATT switch in the OFF position, the EMER LTG switch in the
OFF or SEAT BELT position, there must be no emergency lights illuminated.
(2) Put the EMER LTG switch in the ON position.
(a) The emergency lights must illuminate.
(3) Put the EMER LTS switch in the ARM position
(a) The emergency lights must stay illuminated.
(4) Apply 28 VDC power to airplane, set Batt switch ON, and make sure that the EMERG LIGHTS circuit breaker CB247
(Airplanes -0001 thru -0173) or CB568 (Airplanes -0174 and On) located on the aft main power junction box is engaged.
(a) The emergency lights must extinguish.
(b) The EMER LTS switch amber NOT ARMED light must remain extinguished.
(5) Set the PASS SAFE (S59) switch to ON.
(a) The emergency lights must illuminate.
(6) Set the PASS SAFE (S59) switch to OFF.
(a) The emergency lights must extinguish.
(7) Put the EMER LTS switch in the OFF position.
(a) The emergency light switch amber NOT ARMED light must illuminate.
(b) The emergency lights must remain extinguished.
(8) The emergency lights must remain extinguished.
B. Emergency Battery Pack Inertia "G" Switch Operational Test
NOTE: An inertia "G" switch is mounted inside of each of the two battery packs. You can reset an inertia "G"
switch that is tripped without opening the battery pack, through an access hole in the battery pack
cover. The battery packs are mounted inside the lower left sidewall ducting. Airplanes -0001 thru -0126
except Airplanes incorporating SB650-33-10, forward end of battery packs is at FS 348.00 and FS 240.00
respectively. Airplanes -0127 and On and airplanes -0001 thru -0126 incorporating SB650-33-10, forward
end of battery packs is at FS 314.20 and 227.70 respectively.
(1) Make sure that the PASS SAFE (S59) switch is set to OFF.
(2) Remove the left passenger compartment sidewall panel to get access to the forward and aft battery pack. Refer to Chapter
25, Passenger Compartment Upholstery and Trim - Maintenance Practices.
(3) Remove the screws securing each battery pack in the ducting. Pull battery packs from the lower ducting. Do not disconnect

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the electrical connectors.

(4) Push the reset switches to make sure that the inertia G-switches are not closed.
(5) With the EMER LTS - FWD and EMER LTS - AFT circuit breakers engaged, DC POWER BATT switch to OFF, apply 28
VDC, +0.5 or -0.5 VDC electrical power to airplane.
(6) Put the DC POWER BATT switch to ON and the EMER LTS switch to OFF. Make sure that the NOT ARMED light is
illuminated and the emergency lights are extinguished.
(7) Make sure that the five circuit breakers located on each battery pack, are engaged.
(8) With EMERG LIGHTS circuit breaker CB247 (Airplanes -0001 thru -0173) or CB568 (Airplanes -0174 and On) located on
the aft main junction box engaged, electrical power applied to the airplane and the EMER LTG switch OFF, the NOT
ARMED light must be illuminated and the emergency light must be extinguished.
(9) Put the EMER LTG switch in the ARM position.
(a) The EMER LTG switch NOT ARMED light must extinguish and the emergency lights must remain extinguished.
(10) Carefully strike the forward emergency battery pack near the inertia "G" switch to activate the "G" switch.
(a) The emergency lights must illuminate.
(11) Reset the inertia "G" switch by depressing the RESET on the battery pack.
(a) The emergency lights must extinguish.
(12) Carefully strike the aft emergency battery pack near the inertia "G" switch to activate the "G" switch.
(a) The emergency lights must illuminate.
(13) Reset the inertia "G" switch by depressing the RESET on the battery pack.
(a) The emergency lights must extinguish.
(14) Put the DC POWER BATT switch to ON, set the EMER LTG switch to OFF and remove electrical power from airplane.
(15) Install the screws securing each battery pack in the ducting
(16) Install the left passenger compartment sidewall panel. If necessary, refer to Chapter 25, Passenger Compartment
Upholstery and Trim - Maintenance Practices
END OF TASK
3. Emergency Cockpit Floodlights and Fire Tray Engine Instrument Lights Functional Test
NOTE: The emergency battery packs must be installed to complete this test. Emergency lighting to be tested
consists of two cockpit floodlights and two fire tray mounted engine instrument lights. The rest of the
emergency lighting does not operate during this test.
A. Functional Test.
(1) Make sure that the COCKPIT FLOOD circuit breaker is disengaged.
(2) Disconnect the left and the right engine generator control unit electrical connectors. Refer to Chapter 24, Direct Current
(DC) Generator and Generator Control Unit - Maintenance Practices.
(3) Apply 28 VDC electrical power to the airplane.
(4) Engage the LH START circuit breaker on the left main circuit breaker panel and RH START circuit breaker on the right
main circuit breaker panel.
(5) Press the LH ENGINE START switch.
(a) The fire tray mounted engine instrument lights and the cockpit floodlights must illuminate while the switch is pressed.
(6) Press the RH ENGINE START switch.
(a) The fire tray mounted engine instrument lights and the cockpit floodlights must illuminate while the switch is pressed.
(7) Install a jumper between pins S and Z (pins *S and J Airplanes -7057 and On) of the right generator control unit
disconnected electrical connector. This will energize the right start control relay.
(a) The fire tray mounted engine instrument lights and the cockpit floodlights must illuminate.
(b) Remove the jumper. The lights must extinguish.
(8) Install a jumper between pins S and Z (pins *S and J on Airplanes -7057 and On) of the left generator control unit
disconnected electrical connector. This will energize the left start control relay.
(a) The fire tray mounted engine instrument lights and the cockpit floodlights must illuminate.

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 Model 650 Maintenance Manual (Rev 38)
33-50-00 (Rev 30)

(b) Remove the jumper. The lights must extinguish.

(9) Disengage the LH START and RH START circuit breakers, and remove electrical power from the airplane.
(10) Connect the electrical connectors to the left and the right generator control units. Refer to Chapter 24, Direct Current (DC)
Generator and Generator Control Unit - Maintenance Practices.
(11) Engage COCKPIT FLOOD circuit breaker.
4. Emergency Lighting Battery Pack Circuit Logic Test
NOTE: This test is designed to make sure there is circuitry integrity prior to installation, and/or to look at suspected
faulty battery packs removed from service.
A. Test Battery Pack Circuit Logic.
NOTE: If you service a new battery, or there is a battery that is known to be fully discharged, a small initial two-
hour charge is required in order to test the battery correctly. Refer to Emergency Lighting Battery Pack
Charging, this section.
NOTE: This test can be completed with use of the Lee Air battery pack tester (76345-1) or the Lee Air battery
pack tester (76345-2) with an external digital voltmeter and ammeter or the Aero Mach battery pack
tester (CJMD333-001) with an external digital voltmeter and ammeter.
NOTE: A 3.5 digit digital voltmeter must be used, if either the Aero Mach battery pack tester (CJMD333-001) or
the Lee Air battery pack tester (76345-2) is utilized as the battery pack test box.
NOTE: A 4.5 digit digital voltmeter must be used as the battery current meter to measure the voltage across
current shunt, if either the Aero Mach battery tester (CJMD333- 001) or the Lee Air battery pack tester
(76345-2) is utilized as the battery pack test box.
(1) Set up battery tester as follows:
(a) Make sure that circuit breaker CB1 is engaged.
(b) Set EMER/APU PACK switch to EMER.
(c) Set POWER switch to OFF.
(d) Set LOAD switch to OFF.
(e) Set ARM switch to OFF.
(f) Set VOLTMETER SELECT switch to position #2.
(2) Make sure that inertial G switch is reset, and disengage circuit breakers CB326, CB327, CB328, CB389, and CB390 on
the emergency battery pack.
(3) If either the Lee Air battery pack tester (76345-2) or the Aero Mach battery pack tester (CJMD333-001) is used as the
battery pack test box, connect the external digital voltmeter and ammeter to the battery pack test box circuit.
(4) Connect external power supply to battery pack test box. Adjust power supply until voltmeter on battery pack tester displays
28.5 VDC, +0.1 or -0.1 VDC.
(5) Connect battery pack tester to the emergency battery pack.
(6) Set ARM switch to ON. Position VOLTMETER SELECT to position #3.
(a) The voltmeter must display zero volts.
(7) Engage circuit breaker CB390.
(a) The voltmeter must display zero volts.
(8) Engage circuit breaker CB328.
(a) The voltmeter must display battery pack voltage.
NOTE: Battery pack voltage varies with the condition of the battery.
(9) Disengage circuit breaker CB328.
(a) The voltmeter must display zero volts.
(10) Engage circuit breaker CB389.
(a) The voltmeter must display battery pack voltage.
(11) Disengage circuit breaker CB389.
(a) The voltmeter must display zero volts.

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 Model 650 Maintenance Manual (Rev 38)
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(12) Set VOLTMETER SELECT switch to position #1.

(a) The voltmeter must display zero volts.
(13) Engage circuit breaker CB326.
(a) Voltmeter must display battery pack voltage.
(14) Disengage circuit breakers CB326 and CB390.
(15) Set VOLTMETER SELECT switch to position #2.
(16) Set POWER switch to ON.
(a) The voltmeter must display 28.5 VDC, +0.5 or -0.5 VDC. Record this voltage.
(17) Set VOLTMETER SELECT switch to position #1.
(18) Engage circuit breaker CB326.
(a) The voltmeter must display from 0.4 to 1.0 VDC less than the voltage recorded in item (16) above. Record this
voltage.
(19) Set VOLTMETER SELECT switch to position #3.
(20) Set ARM switch to ARM.
(21) Engage circuit breakers CB390, CB328 and CB327.
(a) The voltmeter must display zero volts.
(22) Set POWER switch to OFF.
(a) The voltmeter must display battery pack voltage.
(23) Set POWER switch to ON.
(a) The voltmeter must display zero volts.
(24) Carefully strike the battery pack case near the inertia G switch to activate the G switch.
NOTE: Five G's are required to activate the G switch.
(a) The voltmeter must display approximately the same voltage recorded in item (16) above.
(25) Reset the inertia G switch.
(a) The VOLTMETER must display zero volts.
(26) Set POWER switch to OFF.
(27) Disengage all circuit breakers on the emergency battery pack.
(28) Charge the battery pack. Refer to Emergency Lighting Battery Pack Charging.
TASK 33-50-00-760
5. Emergency Lighting Battery Packs Restoration (Capacity Check)
A. Detail Inspection of the Emergency Battery Pack.
(1) Remove the left passenger compartment sidewall panel to get access to the forward and aft battery pack. If necessary,
refer to Chapter 25, Passenger Compartment Upholstery and Trim - Maintenance Practices.
(2) Disconnect the electrical connector on the battery box and remove screws securing battery box to structure.
(3) Examine for security of installation, and signs of corrosion, leakage, or damaged electrical components.
(4) Examine the electrical connector and make sure that the pins and sockets are clean, straight and correctly seated.
(5) Examine the condition of the electrical wire bundle for correct routing and clamping and signs of chafing or other damage.
B. Test Emergency Lights Battery (Capacity).
NOTE: This test is accomplished using the Lee Air Battery Pack Tester (76345-1).
NOTE: An acceptable battery pack is based on its ability to deliver power for a specified load for a specified
time duration. You must do the capacity test on a fully charged battery pack.
NOTE: The minimum time from the beginning of the capacity discharge cycle until the load voltage decreases
to less than 17.0 VDC must not be less than 16 minutes.
NOTE: The battery packs are mounted inside the lower left sidewall ducting. Airplanes -0001 thru -0126 except
Airplanes incorporating SB650-33-10, forward end of battery packs is at FS 348.00 and FS 240.00
respectively. Airplanes -0127 and On and Airplanes -0001 thru -0126 incorporating SB650-33-10, forward

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 Model 650 Maintenance Manual (Rev 38)
33-50-00 (Rev 30)

end of battery packs is at FS 314.20 and FS 227.70 respectively.

CAUTION: Do not initiate capacity test for a minimum of 10 minutes after termination of charging cycle.
(1) Remove the battery pack to be tested from airplane.
(2) On the battery pack, disengage the five circuit breakers CB326, CB327, CB328, CB389, and CB390.
(3) Set up battery tester as follows:
(a) Set POWER ON/OFF switch to OFF.
(b) Disengage circuit breaker CB1.
(c) Set EMER/APU PACK switch to EMER PACK
(d) Set ARM switch to OFF.
(e) Set VOLTMETER SELECT switch to position #3.
(f) Connect the battery tester to the battery pack.
(g) Connect +28.5 VDC to battery pack.
(4) Engage the five circuit breakers CB326, CB327, CB328, CB389, and CB390.
(a) Battery Voltage must be displayed on voltmeter.
(5) Set LOAD switch to ON. Immediately begin timing discharge cycle.
(a) The BATTERY CURRENT METER on the initial discharge must indicate approximately 2.7 amperes of battery
current.
(6) Continuously monitor the voltmeter and record the time required for the voltage across the load to reach 17.0 VDC on the
voltmeter.
(a) Set the load switch to OFF immediately after the voltage reaches 17.0 VDC.
(7) If the load voltage does not remain above 17.0 VDC for at least 16 minutes, an additional charge/discharge cycle must be
performed.
(8) If the battery pack does not pass the 16-minute capacity discharge test after the additional charge/discharge cycle, the
battery pack must be replaced.
(9) Disengage the five circuit breakers on the battery pack and disconnect +28 VDC power from the battery tester.
(10) If the battery pack passes the 16-minute capacity discharge test, it must be fully charged prior to installing it into the
airplane; refer to Emergency Lighting Battery Pack Charging.
C. Charge Battery Pack (Using Lee Air Tester/Charger (76345-1)) (Refer to Figure 501).
(1) On the Battery pack, make sure that the inertia "G" switch is reset by depressing the RESET switch. The RESET is visible
through the access hole in the cover.
(2) Disengage the five circuit breakers CB326, CB327, CB328, CB389, and CB390 on the battery pack.
(3) On the tester/charger, disengage CB1 circuit breaker and place the switches in the following positions.
(a) Set POWER switch to OFF.
(b) Engage circuit breaker CB1.
(c) Set EMER/APU PACK switch to EMER.
(d) Set ARM switch to OFF.
(e) Set VOLTMETER SELECT switch to position #2.
(f) Set Load switch to OFF
(4) Connect 28.5 +0.1 or -0.1 VDC to the battery tester/charger.
(a) The voltage can be examined at the voltmeter.
(5) Engage the five circuit breakers CB326, CB327, CB328, CB389, and CB390 on the battery pack
(6) Set POWER switch to ON.
(a) Battery charge current must now be displayed on the ammeter of the tester/charger.
NOTE: If battery charging current is more than 0.500 amperes after one minute, terminate the charge
and replace the battery pack.
(7) Charge the battery pack until battery charging current decreases to approximately 120 ma if battery charges for at least a

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 Model 650 Maintenance Manual (Rev 38)
33-50-00 (Rev 30)

total eight hours. It is recommended that the Lee Air Battery Tester/Charger (76345-1) be used only for charging battery
packs in the eight hour mode.
(8) At the end of the charging period, set the POWER switch to OFF.
(9) Disengage the five circuit breakers CB326, CB327, CB328, CB389, and CB390 on the battery pack.
(10) If required, perform the battery pack capacity test.
(11) Reinstall battery pack.
NOTE: Fully charge the battery pack before it is installed in the airplane.
(12) Restore access to the forward and aft battery pack by installing the left passenger compartment sidewall panel. If
necessary, refer to Chapter 25, Passenger Compartment Upholstery and Trim - Maintenance Practices.
D. Charge Battery Pack (Using Lee Air Tester/Charger (76354-1)) (Refer to Figure 501).
NOTE: You can use the locally fabricated battery charger (Figure 501) for this charging procedure.
(1) On the Battery pack, make sure that the inertia "G" switch is reset by depressing the RESET switch. The RESET is visible
through the access hole in the cover.
(2) On the battery pack, disengage the five circuit breakers CB326, CB327, CB328, CB389, and CB390.
(3) On the charger, disengage the circuit breaker and place switches in the following positions.
(a) Set the CHARGE switch to OFF.
(b) Set CHARGE SELECT switch to EMER BAT.
(4) Connect 28.5 +0.1 or -0.1 VDC to the battery tester/charger.
(5) Engage the five circuit breakers CB326, CB327, CB328, CB389, and CB390 on the battery pack.
(6) Set POWER switch to ON.
(7) Charge battery for at least a total of eight hours.
(8) At end of the charging period, set CHARGE switch to OFF.
(9) Disengage the five circuit breakers CB326, CB327, CB328, CB389, and CB390 on the battery pack.
(10) If required, perform the battery pack capacity test.
(11) Install the battery pack.
NOTE: The battery pack must be fully charged before it is installed in the airplane.
(12) Restore access to the forward and aft battery pack by installing the left passenger compartment sidewall panel. If
necessary, refer to Chapter 25, Passenger Compartment Upholstery and Trim - Maintenance Practices.
END OF TASK
6. Emergency Lighting Battery Pack Charging
NOTE: The battery pack must be fully charged prior to installation in the airplane.
NOTE: The emergency lighting battery pack can be charged with use of an Aero Mach battery pack tester/charger
(CJMD333-001), a Lee Air tester/charger (76345-1), a Lee Air charger (76354-1), or from a locally fabricated
charger unit. Refer to Figure 501.
A. Emergency Light Battery Pack Charging (Use either the Lee Air Tester/Charger (76345-1) or the Aero Mach Tester/Charger
(CJMD333-001).
(1) Press the RESET switch on the emergency lighting battery pack to make sure that the inertia G switch is reset. The
RESET is visible through the access hole in the cover.
(2) Disengage circuit breakers CB326, CB327, CB328, CB389, and CB390 on the emergency lighting battery pack.
(3) On the tester charger, disengage CB1 circuit breaker and place the switches in the subsequent positions.
(a) Set POWER switch to OFF.
(b) Set EMER/APU PACK switch to EMER.
(c) Set ARM switch to OFF.
(d) Set VOLTMETER SELECT switch to position #2.
(e) Set LOAD switch to OFF.
(4) Connect 28.5 VDC, +0.1 or -0.1 VDC, to the battery tester/charger, and engage circuit breaker CB1. Voltage can be

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 Model 650 Maintenance Manual (Rev 38)
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examined on the voltmeter.

(5) Engage circuit breakers CB326, CB327, and CB390 on the battery pack.
(6) Set POWER switch to ON.
(a) Battery charge current must be displayed on the ammeter.
NOTE: If battery charging current exceeds 0.500 amperes after one minute, terminate the charge and
replace the battery.
(7) Charge battery pack until battery charging current decreases to 120 mA or battery charges for at least a total of 8 hours.
NOTE: The Lee Air battery charger (76354-1) must be used only for charging battery packs in the eight-
hour mode.
(8) At the end of the charging period, set POWER switch to OFF.
(9) Disengage circuit breakers CB326, CB327, and CB390 on the battery pack.
(10) If required, complete the battery pack capacity test; refer to Emergency Lighting Battery Pack Capacity Test, this section.
B. Charge Battery Pack (Use the Lee Air Battery Charger (76354-1).
NOTE: The locally fabricated battery charger may be used for this charging procedure.
(1) Press the RESET switch on the battery pack to make sure that the inertia G switch is reset.
(2) Disengage circuit breakers CB326, CB327, CB328, CB389, and CB390 on the battery pack.
(3) On the charger, disengage the circuit breaker and place the switches in the subsequent positions.
(a) Set the CHARGE switch to OFF.
(b) Set CHARGE SELECT switch to EMER BAT.
(4) Connect the battery charger to the battery pack.
(5) Connect 28.5 VDC, +0.1 or -0.1 VDC, to the battery charger, and engage the circuit breaker.
(6) Engage circuit breakers CB326, CB327, and CB390 on the battery pack.
(7) Set CHARGE switch to ON to begin charging.
(8) Charge battery pack for at least a total of eight hours.
(9) At the end of the charging period, set the CHARGE switch to OFF.
(10) Disengage circuit breakers CB326, CB327, and CB390 on the battery pack.
(11) Remove 28 VDC power from the battery charger and disconnect the battery pack from the battery charger.
(12) If required, complete the battery pack capacity test. Refer to Emergency Lighting Battery Pack Capacity Test, this section.

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 Model 650 Maintenance Manual (Rev 38)
33-50-00 (Rev 30)

Figure 501 : Sheet 1 : Battery Pack Charger Electrical Schematic

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