MAINTENANCE INSTRUCTIONS

HALON 1 / 1.2 / 2.5 AIR TOTAL

VALIDATION OF OPERATIONS DESCRIBED IN THIS MANUAL

The maintenance operations described in this manual have been checked in
manufacturer's workshops by an exact carrying out of dismantling, reassembly, test and
repair instructions which are detailed in this document. These operations are those in use
at the latest revision date of the document.

MAINTENANCE INSTRUCTIONS
WITH
ILLUSTRATED PARTS LIST

HALON 1 / 1.2 / 2.5 AIR TOTAL

List of Portable Fire Extinguishers

Part No. Type:

74-00 HAL 1.0

74-20 HAL 1.2
74-21 HAL 1.2 (LH)
74-22 HAL 1.2 (AF)
76-00 HAL 2.5

COMPONENT MAINTENANCE MANUAL

Caution

This manual provides the necessary information to perform the repair in an intermediate level
maintenance shop (I-level).
The 3rd level of maintenance (D-level) is not applicable in this manual.

Link to current revision: https://www.johnsoncontrols.com/de_de/-

/media/jci/be/germany/p1-pages/files/cmm.pdf

TOTAL Feuerschutz GmbH

Industriestr. 13
D-68526 Ladenburg
Cage Code: D0243
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Inspection Record Sheet

Inspec. No. Date Performed Inspec.No. Date Performed Total
issued date by issued date by weight

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Record of revisions
inserted
Rev. No Issue date Release Page
Date by
- 01/1987 01/1987 J. Schöbel -

B 02/1999 02/1999 J. Schöbel 1 – 14

C 08/2003 08/2003 H. Bach 1 – 10, 13

D 12/2003 12/2003 H. Bach 11 - 12

E 01/2005 01/2005 H. Bach 1, 3, 5, 11, 12

F 05/2008 05/2008 H. Bach 3, 8, 9

G 03/2011 03/2011 H. Bach 3, 6, 12

H 10/2012 10/2012 H. Bach 6

I 05/2014 05/2014 H. Bach 3, 9, 10, 12

J 07/2015 07/2015 H. Bach 1, 3, 5, 12

K 06/2016 06/2016 H. Bach 3, 4, 5

L 11/2016 11/2016 H. Bach 1, 3, 4, 7, 9 - 12

M 11/2017 11/2017 H. Bach 1 - 16

N 07/2018 07/2018 H. Bach 1, 6, 9

O 09/2018 10/2018 H. Bach 3, 5, 15

P 04/2019 04/2019 H. Bach 3, 15

Q 12/2019 12/2019 H. Bach 2, 3, 11, 15, 16

R 01/2021 01/2021 H. Bach 10

S 05/2022 05/2022 H. Bach 3, 6, 10

T 11/2022 11/2022 H. Bach 3, 13

U 01/2023 01/2023 H. Bach 3, 8, 11

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Record of temporary revisions

Temp. inserted removed Page
Issue date
Rev. No. Date by Date by No.

List of Illustrations

Illustration No. Title Page

1 Sectional model 7

2 Sealing the valve 12

3 Fire extinguisher parts 15

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Service Bulletin / Service Information Letter List

Rev.
SB / SIL No. Type Incorp. Date Title
No.
74-00
74-20 Change of Basic Overhaul for AIR TOTAL
1 (SB) 21.10.2003
74-21 HAL 1 / 1.2 / 2.5 from 6 to 10 years
76-00
74-00
Change Part Number for AIR TOTAL HAL 1 /
74-20
2 (SB) 20.01.2005 1.2 / 2.5
74-21
76-00
74-00
Missing point at weight specification on
74-20
3 (SB) 27.06.2011 check note label for AIR TOTAL HAL 1 / 1.2 /
74-21
2.5
76-00
4 (SB) 74-00 17.10.2013 Different part numbers for AIR TOTAL HAL 1

5 (SB) 01 74-20 07.12.2016 AIR TOTAL Service Bulletin 2016-01

74-00
SBNO 74-20 Change of PN for valve Air TOTAL HAL 1 /
02 26.09.2018
01/2018 74-21 1.2 / 2.5
76-00

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Table of contents
Title Page

Cover page……………………………………………………………………….……….. 1

Inspection record sheet…………………………………………………………………... 2

Record of revisions………………………………………………………….................... 3

Record of temporary revisions……………………………………………...................... 4

List of illustrations…………………………………………………………...................... 4

Service Bulletin / Service Information Letter List………………………...................... 5

Table of contents…………………………………………………………........................ 6

Description…………………………………………………………………………............ 7

Operating instructions…………………………………………………………………….. 8

Technical data……………………………………………………………………………… 8

Inspection regulations……………………………………………………………………… 9

Disassembly, cleaning and reassembly…………..…………………………………….. 10

Filling instructions………………………………………………………………………….. 11

Filling instructions………………………………………………………………………….. 12

Storage……………………………………………………………………………………… 13

DOT requirements…………………………………………………………………………. 13

Parts list……………………………………………………………………........................ 14

Parts list illustration…………………………………………………………..................... 15

Annex temperature curves………………………………………………………………... 16

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Description (see illustration 1)

(1) Portable fire extinguishers type HAL 1, HAL 1.2 and HAL 2.5 are intended for use in
aircraft pilot- and passenger cabins.
They are filled with HALON 1211. The fire extinguishers are approved for the attack
on flammable solids, flammable liquids, flammable gases and for fires in the presents
of electrical tensions up to 1000 Volt.
The extinguishers are designed for a one hand operation.

(2) Range of application

(a) Fire Class
ABC
(b) Extinguishing agent
HALON 1211

(3) The fire extinguisher consists of 3 main components

(a) The steel container, pressure tested to 36 bar (522 psi), painted red RAL 3000.
(b) The discharge valve with siphon tube and pressure gauge.
The valve is pressure lever operated and can be shut-off.
The carrying handle is movable.
(c) The extinguishing agent HALON 1211 is nitrogen super pressurized.
Filling pressure: 11 bar (156.5 psi) at 15°C (59°F).

Illustration 1 (Sectional model)

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Operating instructions

When held in place with a strap, open fastener and remove extinguisher from bracket. Bent
down safety lever (black), remove seal wire and than squeeze release lever (red). Attack fire with
the discharging extinguishing agent.

Attack the fire starting from front. Discharge agent in shots according to requirements.

Technical data

Part. No. Dimensions Weight w/o Weight bracket Nominal Container Filling Discharge Heights
bracket and and fastening pressure test time
fastening strap strap approx. by 15°C/ press. approx.
Height Dia. Kg Lbs Kg Lbs 59°F Kg Lbs
265mm 82mm 11 bar 36 bar 20,000m
74-00 10.4 in. 3.2in. 1.99 * 4.39 0.21 0.46 156.5 psi 522 psi ** 1 2.2 7 sec 65.616 ft.
265mm 82mm 11 bar 36 bar 20,000m
74-20 10.4 in. 3.2in. 2.19 * 4.83 0.21 0.46 156.5 psi 522 psi ** 1.2 2.65 9 sec 65.616 ft.
265mm 82mm 11 bar 36 bar 20,000m
74-21 10.4 in. 3.2in. 2.19 * 4.83 0.5 1.10 156.5 psi 522 psi ** 1.2 2.65 9 sec 65.616 ft.
265mm 82mm 11 bar 36 bar 20,000m
74-22 10.4 in. 3.2in. 2.19 * 4.83 0.21 0.46 156.5 psi 522 psi ** 1.2 2.65 9 sec 65.616 ft.
380mm 100mm 11 bar 30 bar 20,000m
76-00 15 in. 4in. 4.02 * 8.86 0.41 0.90 156.5 psi 435 psi 2.5 5.51 10 sec 65.616 ft.

* for exact weight see the check note label on the extinguishers backside.
** acc. CFR 173.309 (C).(4). Test pressure must be three times charged pressure (11.5 bar/166.8 psi)
at 21ºC/70ºF and not less than 120 psi.

(1) Operating temperature range

All fire extinguishers can be operated at temperatures of between -40°C and +70°C
(-40°F and +158°F).

(2) Throw distance

Throw distance for the extinguishers 74-00, 74-20, 74-21, 74-22 and 76-00 is 3.50 m
(11.5 Ft) at +20°C (+68°F).

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Inspection regulations
In case of security relevant damages the fire extinguisher has to be scrapped immediately.
If the pressure is reduced the fire extinguisher has to be basically overhauled immediately.
(1) Pre-flight inspection
Check the pressure gauge. At room temperature the indicator must be in the green section.
The seal wire on the safeguard lever must not be damaged.

(2) Periodical check

The inspection should be carried out every 2 years, or in shorter intervals, depending on
internal regulations.

• Integrity of wire seal visual inspection

• Condition of extinguisher, mounting bracket and visual inspection

fastening strap

• Legibility of label visual inspection

• Container pressure / gauge visual inspection

At room temperature the pointer must be in the
green section of the dial.

• Weight control / scale

Permissible deviation: 2% of fill capacity / year, but not more than 10% of fill capacity
(For exact weight see the check note label on the extinguishers backside).
(3) Characteristics after 5 years
After expiration of 5 years, in case of filling / refilling, the container of the fire extinguisher has
to be inspected inside. Should defects be detected, the extinguisher has to be hydrostatically
pressure tested.

(4) Basic overhaul

Container hydrostatic pressure test
All fire extinguishers, listed in that maintenance procedure instruction, must be hydrostatically
pressure tested at regular 10 year intervals. The 10 year period starts with the date of
production of the extinguisher (see label on back). Should defects be detected at a regular
inspection, this pressure test must be performed earlier. These tests shall only be carried out
by an authorized aviation equipment inspector, well adverted with the safety standards
applicable to this test. Furthermore, also required is an adequate room and the necessary
test equipment. After the hydrostatic pressure test the cylinder has to be desiccated inside.
If the second hydrostatic pressure test is due, the manufacturer recommends to replace the
extinguisher!
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Disassembly, cleaning and reassembly

• Empty the extinguisher (observe environmental protection regulations concerning HALON

1211).

• Unscrew valve (60*, 60A*) with open-end wrench size 17.

• Visually inspect valve, container thread and O-ring seat for damage.
If discoloration or corrosion is found on the riser pipe, we recommend replacing the entire
valve.

• Press operation lever and check mobility of valve spindle.

• Visually inspect inside of container for corrosion and damage.

• Screw valve with new O-ring (20*) back on to the container. (Apply a light layer of acid
free Vaseline to thread and O-ring). Torque: 30 Nm

• Clean container. Check label, mounting bracket and fastening strap for damage.

* see page 15 fire extinguisher parts list

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Filling instructions

The fire extinguisher shall only be refilled by an aviation approved maintenance organisation.

When filling HALON extinguishers the filling station must observe the following instructions:

(1) Determining net weight:

After assembly the empty extinguisher must be placed on a scale to determine the
weight. This net weight must be entered in the check note.

(2) Refilling:

Place the extinguisher on a scale and connect it to the fill station. During the filling process
the release lever of the extinguisher must be held down with a clamp. The weight of this
clamp must be taken into consideration in the weighing process.

The extinguishing agent is filled according to weight. Care must be taken to observe the
permissible fill tolerances.

Portable Fire Extinguishers:

HAL 1 1 Kg HALON 1211 (+0 -0.02 kg)

HAL 1.2 1.2 Kg HALON 1211 (+0 -0.02 kg)
HAL 2.5 2.5 Kg HALON 1211 (+0 -0.02 kg)

After the filling the extinguisher must be pressurized with gaseous nitrogen (99.0 to 99.8
degree of purity, dew point -40°C, (-40°F)). The pressurization for HAL 1, HAL 1.2 and
HAL 2.5 should be according to temperature-pressure curves T565*.

The nominal fill pressure at +15°C is 11 bar (mark in green section of gauge dial). Than
move the closed extinguisher horizontally back and forth to mix HALON and nitrogen
together. In this process the container pressure drops. Depressurize the extinguisher to
the specified pressure. Remove the clamp from container release lever. Secure release
lever. The fill line can than be depressurized and also closed.

* see page 16

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(3) Determination of total weight:

After the fill process is completed and the extinguisher disconnected from the fill line, the
extinguisher must be placed back on the scale again to determine the total weight. This
weight must be entered in the inspection record card and on the extinguisher check note
(when weighing the extinguisher, the weight of seal, seal wire and the approval label must
be included).

Seal the extinguisher (Seal wire tensile strength 40 N).

Illustration 2 (Sealing the valve)

(4) Acceptance of filled extinguisher:

Acceptance and clearance of the extinguisher must be made by authorized staff.

Acceptance test:

• General visual inspection of the extinguisher

• Checking operating pressure (see page 5 technical data)
• Tightness control. Checking the unit after 1 week in storage

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Storage

The storage temperature shall not exceed 70°C (158°F). Ambient air should be dry and free of
corrosion causing components. The extinguisher must be inspected every 2 years (or in shorter
periods according to internal regulations) as described in item 1.

DOT requirements

For any transportation by road, air or sea to, from and within USA an approval from DOT is
mandatory. The marking “MEETS DOT REQUIREMENTS” on the fire extinguisher confirms the
approval.

(1) AIR TOTAL HAL 1 74-00

HAL 1.2 74-20
HAL 1.2 (LH) 74-21
HAL 1.2 (AF) 74-22

Above mentioned fire extinguishers, produced before May 2016 are not marked with
“MEETS DOT REQUIREMENTS”. Before transportations the following actions on this fire
extinguishers have to be performed:

- The fire extinguisher needs to be marked with label DOT-SP 20248

(PN 0074-20-1000 / ident. 256108).
Labels can be ordered from:
TOTAL Feuerschutz GmbH
Industriestraße 13
68526 Ladenburg
GERMANY

- If the hydrostatic pressure test is requested, it has to be done with 36 bar (see
technical data page 8). The label “DOT-SP 20248” needs to be replaced with
the marking “MEETS DOT REQUIREMENTS”.

Above mentioned fire extinguishers, produced after May 2016, are not concerned from this
measure. For this fire extinguishers the correct labelling occurred during production.

(2) AIR TOTAL HAL 2.5 76-00

Above mentioned fire extinguisher is not DOT approved. Nevertheless, transportation by

road, air or sea to, from and within USA is allowed with DOT-SP 20439.

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Parts List (see page 15)

This parts list contains all subassemblies and components of the above listed fire extinguishers.

Definition of parts list:

(1) Item numbers

The first number in the first line is the number of the depicted extinguisher.
The second number is the item number shown on illustration 3.
A stroke in front of the item number indicates that this part is not shown on the
illustration.

(2) Part number

Manufacturers original part number.

(3) Ident number

Manufactures EDP-number

(4) Airlines part number

This section remains free for use of the airline

(5) Description
The section description contains the name of every subassembly or extinguisher
component.

(6) EFF-Code
Section EFF-code refers to the association of similar subassemblies / components.
These parts are identified with the letters A, B, C.
Is a component used in all extinguishers this section remains empty.

(7) Number per unit

Number of identical pieces per extinguisher.

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Parts List Illustration

Item No. Part No. Ident Airlines Description EFF- Number
No. part No. Code per unit
10 74-00 821166 Extinguisher HAL 1 A
10A 74-20 821164 Extinguisher HAL 1.2 B
10A 74-21 821226 Extinguisher HAL 1.2 (LH) B
10A 74-22 821495 Extinguisher HAL 1.2 (AF) B
10B 76-00 821165 Extinguisher HAL 2.5 C
20 E000-02785 120101 O-ring 1
30 0074-45 240166 Instruction label 1
40 0074-46 240169 Check note label 1
40A 0074-47 255479 Protective foil 1
50 0074-48-1000 256109 Hazard note 1
60 0074-U12 621091 Valve assembly HAL 1 / 1.2 A, B 1
alternative 0074-U13 621091 Valve assembly HAL 1 / 1.2 A, B 1
60A 0076-U04 621303 Valve assembly HAL 2.5 C 1
alternative 0076-U13 621304 Valve assembly HAL 2.5 C 1
70 E000-11936 220295 Copper seal wire 1
70A E000-00101 120006 Plastic seal green 1
80 0140-00 621139 Bracket HAL 1 / 1.2 * A, B 1
80 0140-01 256055 Bracket HAL 1 / 1.2 * (AF) A, B 1
80A 0119-2 621101 Bracket HAL 2.5 * C 1
80B 0140-02-1000 254303 Bracket HAL 1.2 (LH) * B 1
80C 0140-03-1000 255295 Bracket HAL 1.2 CFK (LH) * B 1
90 0140-U51 254076 Fastening strap HAL 1 / 1.2 A, B 1
90A 0119-2-U51 254077 Fastening strap HAL 2.5 C 1
90B 0140-02-1010 254304 Fastening strap HAL1.2 (LH) B 1
* installation with fastening strap

Illustration 3 (Fire extinguisher parts)

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Temperature Curves

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