24-38-53 COMPONENT MAINTENANCE MANUAL WITH

(F6177)
12, Rue Sadi Carnot - 93170 Bagnolet - France
Tél. (33) (0)1 49 93 19 18 - Fax (33) (0)1 49 93 19 58
COMPONENT MAINTENANCE
MANUAL WITH
ILLUSTRATED PARTS LIST
AIRCRAFT BATTERY
P/N 405CH
Revision 3
Date of issue : May 20/2002
24-38-53
Title page - page 1
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
PAGE INTENTIONALLY LEFT BLANK
24-38-53
Title page - page 2
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
RECORD OF REVISIONS
REVISION
No.
1
ISSUE
DATE
Dec 20/02
INSERTED
DATE
BY
Dec 20/02
SAFT
2
Sep 30/05
Sep 30/05
SAFT
3
Jul 01/08
Jul 01/08
SAFT
REVISION
No.
ISSUE
DATE
24-38-53
INSERTED
DATE
BY
ROR Page 1
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
PAGE INTENTIONALLY LEFT BLANK
24-38-53
ROR Page 2
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
RECORD OF TEMPORARY REVISIONS
TEMPORARY
REV. No.
PAGE
NUMBER
ISSUE
DATE
BY
DATE
REMOVED
24-38-53
BY
RTR Page 1
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
PAGE INTENTIONALLY LEFT BLANK
24-38-53
RTR Page 2
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
SERVICE BULLETIN LIST
NUMBER
SIL 4.99
BRIEF DESCRIPTION
TYPE AFFECTED
Maintenance Interval and extension
procedure
24-38-53
SBL Page 1
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
PAGE INTENTIONALLY LEFT BLANK
24-38-53
SBL Page 2
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
LIST OF APPROVED REPAIRERS
TRADE NAME
ADDRESS
24-38-53
LOAR Page 1
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
PAGE INTENTIONALLY LEFT BLANK
24-38-53
LOAR Page 2
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
LIST OF EFFECTIVE PAGES
CONTENT
PAGE
DATE OF
LATEST
REVISION
TITLE PAGE
1
2
Jul 01/2008
Blank
RECORD OF REVISIONS
1
2
Jul 01/2008
Blank
RECORD OF TEMPORARY REVISIONS
1
2
Jul 01/2008
Blank
SERVICE BULLETIN
LIST
1
2
Jul 01/2008
Blank
LIST OF APPROVED
REPAIRERS
1
2
Jul 01/2008
Blank
LIST OF EFFECTIVE
PAGES
1
2
Jul 01/2008
Jul 01/2008
TABLE OF CONTENTS
1
2
Jul 01/2008
Jul 01/2008
TABLE OF ILLUSTRATIONS
1
2
Jul 01/2008
Jul 01/2008
INTRODUCTION
1
2
3
4
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
1
2
3
4
5
6
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Blank
DESCRIPTION AND
OPERATION
CONTENT
PAGE
TESTING AND FAUL- 1001
TISOLATION
1002
1003
1004
1005
1006
1007
1008
1009
1010
1011
1012
1013
1014
DATE OF
LATEST
REVISION
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
DISASSEMBLY
3001
3002
3003
3004
Jul 01/2008
Jul 01/2008
Jul 01/2008
Blank
CLEANING
4001
4002
4003
4004
Jul 01/2008
Jul 01/2008
Jul 01/2008
Blank
CHECK
5001
5002
5003
5004
5005
5006
5007
5008
5009
5010
5011
5012
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
24-38-53
LEP Page 1
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
LIST OF EFFECTIVE PAGES
CONTENT
PAGE
REPAIR
6001
6002
DATE OF
LATEST
REVISION
Jul 01/2008
Jul 01/2008
ASSEMBLY
7001
7002
7003
7004
7005
7006
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Blank
FITS AND CLEARANCE
8001
8002
Jul 01/2008
Blank
SPECIAL TOOLS,
FIXTURES AND
EQUIPMENT
9001
9002
9003
9004
9005
9006
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Blank
ILLUSTRATED
PARTS LIST
10001
10002
Jul 01/2008
Blank
INTRODUCTION
10003
10004
10005
10006
10007
10008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
VENDOR CODE
INDEX
10009
10010
Jul 01/2008
Blank
ALPHA NUMERICAL
INDEX
10011
10012
Jul 01/2008
Blank
CONTENT
PAGE
DATE OF
LATEST
REVISION
10001-0 Jul 01/2008
10001-1 Jul 01/2008
DETAILED
PARTS LIST
STORAGE (INCLU15001
DING TRANSPORTA- 15002
TION)
15003
15004
15005
15006
24-38-53
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Jul 01/2008
Blank
LEP Page 2
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
TABLE OF CONTENTS
INTRODUCTION
1
2
3
4
6
7
8
PAGE
1
1
1
2
2
3
3
4
- General
- How to Use this Manual
- Measure
- Units of Measure
- Abbreviations
- Definition
- Disposal
DESCRIPTION AND OPERATION
1 - Description
1
1
TESTING AND FAULT ISOLATION
1 - General
2 - Testing
3 - Charge
4 - Discharge
5 - Fault isolation
SCHEMATIC AND WIRING DIAGRAMS
DISASSEMBLY
1
2
3
4
5
1001
1001
1001
1008
1010
1010
NOT APPLICABLE
- General
- Safety
- Risks
- Safety measure
- Disassembly
3001
3001
3001
3001
3002
3002
- General
- Equipment required
- Materials
- Cleaning procedure
- Lubrication
4001
4001
4001
4001
4001
4003
CLEANING
1
2
3
4
5
CHECK
1 - General
2 - Maintenance steps in workshop
5001
5001
5001
1 - General
2 - Equipment
6001
6001
6001
REPAIR
24-38-53
TOC Page 1
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
PAGE
6001
3 - Repairs
ASSEMBLY
7001
7001
7001
1 - General
2 - Assembly procedure
FITS AND CLEARANCES
1 - Torque table
8001
8001
SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1 - General
2 - Special tools, fixtures and equipment
3 - Consumables
9001
9001
9001
9005
ILLUSTRATED PARTS LIST
1 - Introduction 2 - Vendor code index 3 - ALPHA Numerical index 4 - Detailed parts list -
10001
10003
10009
10011
10001-0
SPECIAL PROCEDURES
NOT APPLICABLE
REMOVAL
NOT APPLICABLE
INSTALLATION
NOT APPLICABLE
SERVICING
NOT APPLICABLE
STORAGE (INCLUDING TRANSPORTATION)
1 - Storage
2 - Storage procedure
3 - Servicing after storage
4 - Transportation
REWORK (service bulletin instructions)
15001
15001
15001
15005
15005
NOT APPLICABLE
24-38-53
TOC Page 2
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
TABLE OF ILLUSTRATIONS
Figure
1
- 405CH Battery
PAGE
3
Figure
2
- Identification plate
4
Figure
3
- Overall dimensions
5
Figure 1001 - Preliminary Functional Tests
1003
Figure 1002 - Insulation Check
1004
Figure 1003 - Insulation Parameters
1005
Figure 1004 - Cell connections
1008
Figure 5001 - Periodical check
5003
Figure 5002 - Level adjustment with a syringe and calibrated nozzle
5004
Figure 5003 - Regular check
5007
Figure 5004 - General overhaul
5011
Figure 7001 - Liner spacer kit installation
7003
Figure 7002 - Cell installation
7005
Figure 9001 - Polyamide key for vent valve (T01)
9002
24-38-53
TOI Page 1
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
Figure 9002 - Syringe with nozzle (T02)
PAGE
9002
Figure 9003 - Equalizing resistor (T03)
9003
Figure 9004 - Cell extraction tool (T04)
9004
Figure
10001-0
1
- 405CH BATTERY
Figure 15001 - Short term storage
15003
24-38-53
TOI Page 2
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
DESCRIPTION AND OPERATION
1. Description
A. General
The alkaline battery has 20 vented nickel-cadmium CVH400KA cells with welded polyamide
cases.
The battery is connected to the aircraft systems. You can use it:
(1) To start the engine or the APU in reference to the aircraft system.
(2) On the ground, before supplying electrical power to the aircraft systems.
(3) In flight, if a malfunction or a failure occurs in the power supply system.
NOTE: The 28 VDC electrical system charges the battery in the aircraft
The figure and item numbers used in this chapter correspond to those of the ILLUSTRATED
PART LIST.
B. Characteristics
(1) Technical data
Nominal voltage
24 V
Rated capacity C1Ah
40 Ah (see Note below)
Battery terminals
Connector according to MS 3509
Electrolyte
Solution of KOH
Consumable volume of electrolyte
60 cm3 (3.66 in3) per cell
Maximum dimensions of the battery
- Length
- Width
- Height
268.4 mm (10.57 in)
300 mm (11.8 in)
262 mm (10.31 in)
Battery maximum weight
34.8 kg (76.7 lbs)
Note: 40 Ah at 1 h rate noted as 40 C1Ah or 40 C1Ah.
Current value equivalence : 40 A = 1 C1A and 4 A = 0.1 C1A for this 40 C1Ah battery.
24-38-53
Page 1
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
(2) Operational characteristics
- Operating temperature : - 40 to + 71 °C (- 40 to + 160 °F)
(3) Electrical characteristics
List of all values used to service the battery:
Item
Value
Use for
1 C1A
40 A
Charge/Discharge
0.5 C1A
20 A
Charge
0.1 C1A
4A
Charge
C. Detailed description
The battery has 20 CVH400KA (130) cells housed in a stainless steel box with 2 vents and
2 handles.
The box (250) is lined with thin sheets of insulation and wedges (200). The cells are kept upright
by means of a molded silicone elastomer part (040) fastened to the cover which presses against
the top of the cells. Cells are interconnected by rigid, nickel-plated copper links (080 thru 110).
The connector (230) connects the battery to the aircraft.
The cover (030), which can be removed, is attached to the box (250) by four latches.
24-38-53
Page 2
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
Filling instruction plate
Cover
Connector
Box
Identification plate
405CH Battery
Figure 1/TASK 24-38-53-991-001
24-38-53
Page 3
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
Identification plate
Figure 2/TASK 24-38-53-991-002
24-38-53
Page 4
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
Overall dimensions
Figure 3/TASK 24-38-53-991-003
24-38-53
Page 5
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
PAGE INTENTIONALLY LEFT BLANK
24-38-53
Page 6
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
INTRODUCTION
1. General
A. This manual is written to the ATA Specification 100 and in AECMA Simplified English. IS units of
measure are used in this manual, with imperial units in parentheses.
B. This manual describes maintenance on components in a workshop. It does not describe
maintenance on components when they are installed in aircraft.
C. Only approved persons with the necessary skills can do maintenance tasks described in this
manual.
D. Maintenance Task Oriented Support System (MTOSS) task and subtask identification is used in
this manual. Maintenance tasks and other data have special MTOSS numbers for the use of
Electronic Data Processing (EDP). MTOSS numbers can be ignored by the user of the manual.
E. This manual contains:
- Technical data for components.
- Maintenance and repair procedures for components.
- An Illustrated Parts List (IPL) with data for parts of components. Parts are identified in all sections of the manual by the IPL figure and item number.
F. We make sure of DISASSEMBLY, TESTING AND FAULT ISOLATION, and ASSEMBLY
procedures by doing them.
2. How to Use this Manual
A. Make sure the manual contains information applicable to your component. Look for the part
number on the Title Page.
B. If you need to identify a part or find a part number, refer to the IPL, which has an Introduction
chapter showing the procedure.
C. The instructions in this manual must be used for all components maintenance. Read all the
applicable WARNINGS and CAUTIONS before you do the work on the component.
24-38-53
INTRO Page 1
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
3. Measure
Measure given in this manual are taken from original manufacturing drawings.
Quantities are given in I.S. Units followed by U.S. Units in parentheses.
4. Units of Measure
A. I.S. Units
A
Ah
C1A
C1Ah
g
min
N
N.m
VDC
°C
%
Ω
Ampere
Ampere hours
Rated current
Rated capacity for an hour
Gram
Minute
Newton
Newton meter
Volt direct current
Degree Celsius
Per cent
Ohm
B. U.S. Units
ft
in
lb
lbf.in
°F
Foot
Inch
Pound
Pound force inch
Degree Fahrenheit
C. Multiplying Prefixes
μ
m
da
k
M
Micro
Milli
Deca
Kilo
Mega
24-38-53
INTRO Page 2
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
5. Abbreviations
The abbreviations given below are used in this manual:
ATA
DIA
FIG.
IPL
MAX.
MFR
MIN.
NO.
OD
P/N
PARA.
REF.
S/A
TBD
AIR TRANSPORT ASSOCIATION OF AMERICA
DIAMETER
FIGURE
ILLUSTRATED PARTS LIST
MAXIMUM
MANUFACTURER
MINIMUM
NUMBER
OUTSIDE DIAMETER
PART NUMBER
PARAGRAPH
REFER TO
SUBASSEMBLY
TO BE DEFINED
6. Definition
This paragraph describes the warnings used in this manual.
Warnings call attention to use of materials, steps procedures, or limits, which must be followed precisely to avoid injury to persons.
Cautions call attention to steps procedures which must be followed to avoid damage to equipment.
Notes call attention to procedures which make the job easier.
24-38-53
INTRO Page 3
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
7. Disposal
Ni-Cd batteries contain :
- nickel,
- cadmium,
- potassium hydroxide.
They must therefore be discarded or used again, in agreement with local legislation. For more information, contact your local SAFT supplier.
24-38-53
INTRO Page 4
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
TESTING AND FAULT ISOLATION
1. General
This chapter gives the tests and inspections necessary to find the condition of the unit removed for
unscheduled maintenance. The test procedure, given in the FAULT ISOLATION TABLE, states for
each test a specific procedure which specifies all relevant parameters.
The figure and item numbers in this chapter agree with those of the ILLUSTRATED PARTS LIST.
TASK 24-38-53-700-801
2. Testing
A. Equipment
(1) Standard tools
- Standard mechanic’s tools.
- Safety gloves.
- Protective goggles.
- Safety shoes.
- Eye wash.
- Protective apron.
- Air compressor with manometer (graduation 0.1 to 1 Bar).
(2) Special tools
When special tools are used in this chapter, they are identified by a code number listed in the
chapter SPECIAL TOOLS, FIXTURES AND EQUIPMENT.
- charge/discharge bench (constant current 0 - 60 A).
- power supply: 0 - 45 V, range 0 - 60 A.
(3) Instruments
- A multimeter, range 2 V - 50 V, accuracy 1%.
- A megohmeter, range 0 - 50 MΩ (voltage 250 VDC), accuracy 3%.
24-38-53
Page 1001
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
(4) Check conditions
- Ambient temperature: 23 + 5 °C (73 + 9 °F).
- Pressure: 85 to 106 kPa.
- Relative humidity: < 85 %.
B. Precautions
You must always do regular maintenance. It is then necessary to obey these precautions to make
sure that you have correct operation of the battery:
- Do not install the battery in an aircraft which is too hot.
- Carefully obey the instructions that give the aircraft procedure to make sure that the flow of air
is good.
- Make sure of the capacity of the battery regularly.
- Charge the battery in a battery shop.
- Maintenance must be done (Refer to CHECK chapter), specially to make sure of:
- Level of electrolyte. Specially when ambient temperature is high, time between maintenance must decrease.
- Tightness of the connection nuts.
- Correct charging.
24-38-53
Page 1002
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
SUBTASK 24-38-53-720-001
C. Preliminary Functional Tests (Ref. Fig. 1001)
1
Discharge at 1 V/cell
Tighten the nuts (060)
1 Ω cell shorting 12 h
charge at 1 C1A (40 A)
Yes
see para. 5.B (6)
salt or electrolyte
traces
No
Yes
see para. 5.C (1)
Topping up at the end
of charge
electrolyte in
the box
Yes
see para. 5.C (2)
more than
usual average added in all
cells *
see para. 5.C (3)
more than
30% versus battery
cell average added
in 1 cell
box or cells
damaged
note the voltage of each
cell during the charge
No
Yes
Yes
see para. 5.A (1)
Yes
see para. 5.B (7)
Yes
see para. 5.B (5)
see para. 5.B (3)
Yes
see para. 5.B (4)
Yes
see para. 5.B (5)
Yes
see para. 5.C (4)
24-38-53
Page 1003
Jul 01/2008
voltage of 1 cell
< 1.55 V
capacity check
< 100 % C1Ah
No
No
insulation
between cell and box
< 250 kΩ
Yes
1 or more
cell has a voltage > 0.1 V
than the others
No
No
1 or more cell < 0 V
see para. 5.B (2)
No
No
1 or more cell = 0 V
Yes
No
No
battery
voltage = 0 V
see para. 5.B (1)
No
No
metallic parts
corroded
Yes
Yes
a link or a
nut is too hot
see para. 5.A (3)
No
No
do a General Overhaul
to detect battery fault or
external cause
Preliminary Functional Tests
Figure 1001/TASK 24-38-53-991-005
(*) average in log book must be considered
COMPONENT MAINTENANCE MANUAL
405CH
SUBTASK 24-38-53-720-002
D. Testing procedure
(1) Insulation check (Ref. Fig. 1002-1003)
- Put the megohmeter as specified below:
Insulation Check
Figure 1002/TASK 24-38-53-991-006
- > 250 kΩ under 250 VDC = Min value.
- > 10 MΩ under 250 VDC = value after cleaning and drying.
24-38-53
Page 1004
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
250 KΩ
problem
2 MΩ
Necessary to clean
10 MΩ
Can wait until next
maintenance
In battery maintenance shop
Cleaning necessary
OK
Always required after
cleaning and drying
Cleaning necessary
Acceptable
Examine the cause
(overcharge…)
Insulation Parameters
Figure 1003/TASK 24-38-53-991-007
(2) Polarization test
Charge the battery at 4 A for 1.5 hours.
Keep the battery in "open circuit" condition for 1 hour.
Measure the open circuit voltage of each cell.
If open circuit voltage of any cell is 0 V (or negative), do a supplementary test (refer to
paragraph 4). Then repair.
If every cell has an open circuit voltage that is more than 0 volts, charge the battery.
24-38-53
Page 1005
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
(3) Vent valve test
NOTE : The Vent Valve Test is not required if the full set of used vent valvesis replaced
by a brand new one each year during the General Overhaul or when there is
evidence of electrolyte overflow.
Before you put the vent valve back on the cells, make sure that they operate correctly. Do
these steps:
Install the vent valve (190) with its O-ring on the end of a metal tube which has an applicable
end-piece.
Connect this tube to a supply of compressed air through an adjustable reducing valve.
Adjust the pressure to 0.5 bar (7.25 psi) and put the vent valve into a container of water. Air
bubbles come out when the valve opens. If there are no bubbles, increase the pressure until
you see bubbles. Then decrease the pressure slowly to 0.1 bar (1.45 psi) and monitor the
pressure at which the bubbles stop.
Reject all vent valves that have an opening pressure of more than 0.7 bar (10 psi) or less
than 0.14 bar (2 psi).
Install the vent valve (190) (Refer to ASSEMBLY chapter).
(4) Supplementary test
The first test charge can be unsatisfactory if the electrolyte level is too low in some cells (because the level is not adjusted until the end of this charge). If you find defects, adjust the electrolyte level and do the test below:
NOTE : If you charge the battery more than necessary, you decrease the life of the
cells. Thus, do this special test only if a battery malfunction occurred in the
aircraft, or defects are found during shop maintenance.
- Charge the battery (Refer to one of the procedures given in chapter TESTING AND FAULT
ISOLATION). At the end of the total charge time, continue to charge at 4 A for 5 more hours.
Regularly record the voltage of the cells. The temperature of cells that have damaged separators increases in an important way and continuously. The voltage of these cells continuously decreases to less than 1.55 V.
- Adjust the electrolyte level during the last 30 minutes of charge.
- Discharge at 40 A down to 1 V/cell.
- After this test, discard the defective cells:
- Cells with a voltage of less than 1.55 V at the end of the charge.
- Cells with a voltage that decreases to less than 1 V before one hour of discharge (during the last test discharge).
- Short-circuited cells (zero volts).
24-38-53
Page 1006
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
TASK 24-38-53-800-801
3. Charge
SUBTASK 24-38-53-820-001
A. Flight charge
The decrease of water from the electrolyte is in direct proportion to the overcharge current.
SUBTASK 24-38-53-820-002
B. Ground charge
Do all battery maintenance or overhaul steps in a workshop.
NOTE: I n ad dition to the constant cu rrent me thod of charg ing, other methods that ful ly
charge the battery can be used. HO WEVER, IN EVERY CASE, CELL VOLTAGE
CHECKS (U > 1.55 V) AN D ELEC TROLYTE ADJUSTMENTS MUST BE CARRIED
OUT USING A FINA L CHARGE SEQU ENCE A T CONSTANT C URRENT: 4 A A T
0.1 C1A. If specific instructions are not giv en in the c harger opera ting manual,
SAFT should first be contacted.
WARNING: REMOVE THE COVER TO CHARGE THE BATTERY ON THE GROUND. THIS IS
TO MAKE SURE THAT GAS WILL NOT COLLECT IN THE BATTERY BOX.
110
090
080
100
Cell connections
Figure 1004/TASK 24-38-53-991-008
24-38-53
Page 1007
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
(1) Constant-current charge (Battery fully discharged)
(a) Battery fully discharged
The charge must follow one of the rates described in the table. If the battery voltage in
main charge is less than the minimum voltage after the minimum time, continue to
charge until the voltage is reached.
NOTE : If the battery voltage does not increase sufficiently during the maximum
charge time, refer to the chapter TESTING AND FAULT ISOLATION.
Main charge
Current and duration
Final charge
Minimum voltage
Current and duration
30. V
4 A (0.1 C1A) for a 4 h time
31 V
4 A (0.1 C1A) for a 4 h time
31.4 V
4 A (0.1 C1A) for a 4 h time
4 A (0.1 C1A)
min. 10 h
Times :
max. 12 h
20 A (0.5 C1A)
min. 2 h
Times :
max. 2 h 30 minutes
40 A (1 C1A)
min. 1 h
Times :
max. 1 h 15 minutes
CAUTION: When you charge the battery more than in the table above, you decrease
the life of the cells.
(b) Battery not fully discharged and discharge condition not known.
Discharge at 40 A (1 C1A) down to 20 V. Refer to paragraph DISCHARGE.
Charge : refer to B (1) (a) above constant current charge.
24-38-53
Page 1008
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
TASK 24-38-53-800-802
4. Discharge
Rated capacity
(C1Ah)
40 Ah : minimum value obtained for a fully charged
battery, when discharged at 40 A, down to 20 V.
Other rates
(C1A)
Depending on temperature and time: up to 25 C1A.
TASK 24-38-53-700-802
5. Fault isolation
SUBTASK 24-38-53-760-001
A. Battery electrical faults
PROBLEM
(1) Zero battery open-circuit
voltage
(2) Zero volts with the battery
set to "discharge"
(3) Low insulation
PROBABLE CAUSE
CORRECTION
(a) Defective electrical connector (no contact made)
Examine electrical contacts,
links and tightness of nuts
(refer to CHECK chapter).
(b) Link loose or broken
Make sure the nuts are tight
(refer to CHECK chapter).
(a) Battery fully discharged
Charge the battery.
Do an insulation check (refer to
CHECK chapter).
(b) Battery circuit open or contacts defective
Examine the contacts and links.
Make sure the terminal nuts are
tight (refer to CHECK chapter).
(c) Cell fully dry
Refer to related subsequent
steps.
(a) Leakage of electrolyte
Disassemble and clean the battery (refer to DISASSEMBLY
AND CLEANING chapters).
Do an electrolyte level check
(refer to CHECK chapter).
24-38-53
Page 1009
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
SUBTASK 24-38-53-770-001
B. Cell faults
PROBLEM
PROBABLE CAUSE
CORRECTION
(1) Too much water decrease
for all battery cells.
(a) Charge much more than the
limit or too much charge at high
temperature.
Examine the cause of excessive charge. If necessary,
adjust the maintenance interval.
(2) The variation of water consumption in individual cell
exceed ±30% of the average
consumption for all cells.
(a) More than 30% or more
than the average: leaks from
the cell(s).
Do the supplementary test
(refer to CHECK chapter
para. 2.D.4). If necessary,
replace the cell(s).
(b) 30% (or less) of the
average: cell(s) with damaged
separator(s).
Note the cell location and and
check the level of water comsumption versus other cells at
the next maintenance.
(c) Previous maintenance has
not been done.
(3) A cell has an unsually high
voltage at the start of the
charge.
(a) Dry cell.
When the defect occurs, add
5 cm3 (5 ml) of distilled water to
the cell. Do not adjust more
accurately until the end of the
charge.
NOTE: If you charge a cell with a quantity of electrolyte which is not sufficient, this can
cause temperature to increase very much.
(4) A cell has an unsually low
voltage at the end of the charge
(Less than 1.55 V at 4 A at
+ 20 °C (+ 68 °F)
(a) The cell was operated at
temperatures and charge rates
outside the limits, and the separator is damaged.
Replace the cell (refer to DISASSEMBLY, ASSEMBLY AND
STORAGE chapters).
(5) Low capacity cell (The cell
shows a reversed voltage or a
correct polarity voltage of less
than 1 V after a discharge of
1 hour at 1 C1A).
(a) Usual wear after long operation.
Replace the cell (refer to DISASSEMBLY, ASSEMBLY AND
STORAGE chapters).
(b) Unusual operation, operation at high temperature or
operation with low electrolyte.
Do the supplementary test
(refer to CHECK chapter
para. 2.D.4). If necessary,
replace the cell(s).
24-38-53
Page 1010
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
PROBLEM
PROBABLE CAUSE
CORRECTION
(6) Cell with a swollen case.
(a) Cell operated with low electrolyte level ; deterioration of
separators and damaged
plates.
Replace the cell (refer to DISASSEMBLY chapter).
(7) Cell with zero voltage when
the battery circuit is open.
(a) Short-circuited cell.
Replace the cell (refer to DISASSEMBLY chapter).
24-38-53
Page 1011
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
SUBTASK 24-38-53-750-001
C. Physical faults
PROBLEM
(1) Leakage of electrolyte
PROBABLE CAUSE
CORRECTION
(a) Incorrect adjustment of
level.
Disassemble and clean the battery (refer to DISASSEMBLY
and CLEANING chapters). Do
an electrolyte level check (refer
to CHECK chapter).
(b) Cell polarity incorrect during
high-rate discharge (for example, during the engine start).
Examine the cause of excessive charge.
Disassemble and clean the battery (refer to DISASSEMBLY
and CLEANING chapters).
Do an electrolyte level check
(refer to CHECK chapter).
(c) Too much charge at high
temperature or too much current.
Examine the cause of excessive charge.If necessary, adjust
the maintenance interval.
Disassemble and clean the battery (refer to DISASSEMBLY
and CLEANING chapters).
Do an electrolyte level check
(refer to CHECK chapter).
(2) Electrolyte found in the battery box.
(a) Damaged cell case
Replace the cell if necessary
and refer to related subsequent
steps.
(b) Leakage of electrolyte
Disassemble and clean the battery (refer to DISASSEMBLY
and CLEANING chapters).
Do an electrolyte level check
(refer to CHECK chapter).
24-38-53
Page 1012
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
PROBLEM
(3) Corrosion on the links.
(4) The links are too hot.
PROBABLE CAUSE
CORRECTION
(a) Operation in acid air
Make sure the battery test
bench and the storage areas
have no materials which can
release acid fumes.
(b) Mechanical damage to
nickel plating
Replace the damaged links
(refer to DISASSEMBLY,
ASSEMBLY AND STORAGE
chapters).
(a) Loose terminals nuts
Make sure the nuts are torqued
(refer to CHECK chapter).
24-38-53
Page 1013
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
SUBTASK 24-38-53-750-002
D. Vent valve faults
PROBLEM
PROBABLE CAUSE
CORRECTION
Valve open pressure > 0.7 bar
or the valve stays open.
Clogged valve.
Change the valve.
Valve stays open for a pressure
< 0.14 bar or is not closed.
Pierced valve.
Change the valve.
24-38-53
Page 1014
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
DISASSEMBLY
1. General
NOTE: Refer to chapter TESTING AND FAULT ISOLATION to find the condition of the
component or the possible cause of its malfunction. This will give the necessary level
of disassembly.
WARNING: DO ALL STEPS ON FULLY DISCHARGED BATTERIES (TESTING AND FAULT
ISOLATION CHAPTER).
The figures and items numbers used in this chapter agree with those of the ILLUSTRATED PARTS
LIST.
2. Safety
Different countries have different safety rules. Obey the local rules.
3. Risks
There are three types of risks.
A. Physical
- Handling: The weight is heavy. When you lift it, bend your legs, not your back.
- Use protective shoes.
B. Electrical
- Don’t wear rings, watches, chains, belt buckles.
- Use insulated tools.
C. Chemical
- Electrolyte is very corrosive and can cause dangerous damage to the skin: use gloves.
- Contact with eyes is very dangerous, use protective goggles.
24-38-53
Page 3001
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
4. Safety measure
- The electrolyte compound is caustic and can cause dagerous burns. If it comes in contact with the
skin, flush the touched part with water and make neutral the solution with acetic solution, vinegar or
lemon juice, or with boric acid solution at 10% concentration.
- If the electrolyte touches the eyes, flush them with water for 15 minutes at minimum and call a doctor.
- Electrolyte ingestion can cause damage to the throat and the respiratory tract. Do not try to vomit.
Mix the solution with water or, if possible, with milk. Call a doctor immediately. Do not try to make
someone unconscious drink . Contact with nickel can cause chronic eczema. Inhalation of cadmium
oxide can cause a dry throat, make you cough, cause headaches, vomiting, or pain in your chest.
Persons having inhaled cadmium oxide fumes must get fresh air or take oxygen or must have artificial respiration.
- Potash can cause eczema.
TASK 24-38-53-000-801
5. Disassembly
A. Equipment
(1) Standard tools
- Standard mechanic’s tools.
- Safety gloves.
- Protectives goggles.
- Safety shoes.
- Eye wash.
- Protective apron.
(2) Special tools
When special tools are used in this chapter, they are identified by a code number listed in the
chapter SPECIAL TOOLS, FIXTURES AND EQUIPMENT.
SUBTASK 24-38-53-020-001
B. Disassembly procedure
WARNING: DO ALL STEPS ON FULLY DISCHARGED BATTERIES (TESTING AND FAULT
ISOLATION CHAPTER).
(1) Remove the cover (020)
(2) Removal of a cell
NOTE: In order to prevent a short-circuit, remove a link (090) between two cells.
24-38-53
Page 3002
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
(a) Remove the nuts (060) and the spring washers (070) that attach the links to the cell.
(b) Remove all links (080 thru 110).
(c) Fully engage the end of the special threaded tool (T03) onto one of the cell terminals.
Then pull up to remove the cell.
NOTE: The vent valve must stay tight when the you remove the cell.
(3) Removal of a vent valve (190) (safety cap)
(a) Loosen the vent valve (190) with the special tool (T01).
(b) Remove the vent valve (190) with its O-ring.
(4) Disassembly of the battery
(a) Remove
1. The cover (020).
2. The cells (130).
3. The liner spacers kit (200).
4. The connector (230).
24-38-53
Page 3003
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
PAGE INTENTIONALLY LEFT BLANK
24-38-53
Page 3004
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
CLEANING
1. General
The figure and item numbers used in this chapter agree with those of the ILLUSTRATED PARTS
LIST.
2. Necessary equipment
- Safety gloves.
- Protectives goggles.
- Safety shoes.
- Eye washing.
- Protective apron.
3. Materials
- Ordinary water.
- Distilled water.[MO1]
- Neutral soap.[MO2]
- Non-fluffy swab.
- Non-wire brush.
TASK 24-38-53-100-801
4. Cleaning procedure
WARNING: THE ELECTROLYTE IS DANGEROUS. BE CAREFUL WHEN HANDLING
ELECTROLYTE AND PREVENT SPLASHING. IT IS A STRONG CAUSTIC AGENT
AND CAN CAUSE DANGEROUS BURNS. ALWAYS USE FACE AND EYE
PROTECTION (PREFERABLY A TRANSPARENT FACE MASK, RUBBER GLOVES
AND LONG SLEEVED CLOTHING). IN CASE OF CONTACT WITH SKIN, FLUSH
IMMEDIATELY WITH MUCH WATER. IN CASE OF CONTACT WITH EYES, FLUSH
WITH WATER 15 MINUTES AT MINIMUM AND, IN ALL CASES, GET IMMEDIATELY
MEDICAL ATTENTION.
SUBTASK 24-38-53-160-001
A. Light cleaning
Remove the cover.
If a clean, filtered supply of compressed air is available, do this procedure to clean the cells easily
and quickly: blow with much force across the tops of the cells to remove all dust and light traces
of mineral salts from the box. To prevent short circuits, use a rubber tube or an insulating nozzle.
24-38-53
Page 4001
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
SUBTASK 24-38-53-160-002
B. Full cleaning
Disassemble the battery (refer to "DISASSEMBLY" chapter) and then clean all components.
(1) Cells
Make sure that the vent valve (190) (safety cap) is tight.
Do not soak the cells in water.
To easily remove all the electrolyte and mineral salts from the terminals, the cover and the
sides of the cell cases: clean in warm water with a soft brush.
Rub the cell with a cloth and let dry.
(2) Box and handle
Clean with lightly soapy water, rub with a cloth and let dry.
(3) Nuts, spring washers and links
Clean in warm water with a brush and let dry.
(4) Liner spacer kit
Clean in warm water and let dry.
(5)
Vent valve
CAUTION: YOU MUST CLEAN THE VENT VALVE (190) WHEN THE CELLS ARE ASSEMBLED IN THE BOX.
(a) Remove the vent valve (190) (Refer to "DISASSEMBLY chapter).
(b) Put swab on the cell holes to keep out unwanted material.
(c) Soak the vent valve for some period (during the night, for example) in a container of
distilled water. Do that to remove all salts from the vent hole.
CAUTION: DO NOT USE PETROL, TRICHLOROETHYLENE OR OTHER SOLVENTS.
24-38-53
Page 4002
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
TASK 24-38-53-600-801
5. Lubrication
When the battery is clean (and after installation of the vent valve), put a thin layer of neutral petrolatum (petrolatum that is not acid) or light oil on the terminals and the links. Use a paintbrush.
24-38-53
Page 4003
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
PAGE INTENTIONALLY LEFT BLANK
24-38-53
Page 4004
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
CHECK
1. General
You must do the checks which are necessary to use the Saft batteries in flight and on the ground:
- Periodical check: adjustment of electrolyte levels.
- Regular check: electrical treatment, adjustment of electrolyte levels, and capacity test.
- General overhaul: disassembly, full cleaning, assembly and regular check.
TASK 24-38-53-200-801
2. Maintenance steps in workshop
A. Equipment
(1) Standard tools
- Standard mechanic’s tools.
- Safety gloves.
- Protectives goggles.
- Safety shoes.
- Eye wash.
- Protective apron.
(2) Special tools
When special tools are used in this chapter, they are identified by a code number listed in the
chapter SPECIAL TOOLS, FIXTURES AND EQUIPMENT.
- Power supply 0 - 45 V, 0 - 60 A.
- Discharge bench, constant current 0 - 60 A.
(3) Instruments
- A multimeter, range 2 V and 50 V, accuracy 1%.
- A megohmeter, range 0 - 50 MΩ (voltage 250 VDC), accuracy 3%.
(4) Check conditions
- Ambient temperature: 23 °C ± 5 °C ( 73 ± 9 °F).
- Pressure: 85 to 106 kPa (25.1 to 31.1 InHg).
- Relative humidity: < 85 %.
24-38-53
Page 5001
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
(5) Referenced information
REFERENCE
24-38-53-720-002
DESIGNATION
Insulation check
Polarisation test
Vent valve test
Supplementary test
SUBTASK 24-38-53-210-001
B. Periodical check
If the electrolyte consumption exceeded the approved used between 2 regular check, apply this
periodical check according to Fig 5001.
(1) Charging the battery
(a) Discharge the remaining capacity at 40 A down to a voltage of 20 V at the battery terminals.
(b) When the battery temperature is at usual temperature range, 23 °C ± 5 °C ( 73 ± 9 °F) ,
charge the battery (refer to one of the procedures given in the chapter TESTING AND
FAULT ISOLATION for a fully discharged battery).
(c) During the last 1/2 hour of the charge (while the charge current continues to flow), adjust
the level of electrolyte in the cells (refer to PARA B (2)). Write down the quantity of water
that is added to each cell. The electrolyte level changes with the battery charge. The level changes as if the plates absorbed a part of the electrolyte during the discharge and
released it during the charge. Therefore the level checks are only satisfactory if they are
done almost at the end of the charge (but during the charge). Leakage can occur during
operation if you do not obey these instructions when you add liquid.
(d) Measure the voltage of each cell.
24-38-53
Page 5002
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
PERIODICAL CHECK 2.B
Remove the cover
no
Insulation check
> 2 MΩ
yes
Light cleaning
yes
dust only?
yes
no
U > 21 V
no cell with reversed
polarity
Nut tightness
Salt or electrolyte traces
no
POLARIZATION TEST
Residual discharge
1 V/cell
Charge
General overhaul
figure 5004
no
FAULT ISOLATION
Supplementary test
OK?
Add 5 h overcharge
U > 1.55 V
Adjust electrolyte
Cell voltage before
end of charge
U > 1.55 V
Adjustment of electrolyte level before
end of charge
(volume < 60 cm3)
dispersion < 30 %
yes
yes
Vent valve cleaning
no
General overhaul
figure 5004
with replacement of
faulty components.
If more than 5* original * If 3 or more cells changed ducells, then change all
ring the same check, change all
cells.
cells.
Nut tightness
Battery accepted after
periodical check
Periodical check
Figure 5001/TASK 24-38-53-991-010
24-38-53
Page 5003
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
Adjustment of electrolyte level
WARNING: DO NOT USE ACID OR ACIDULATED WATER to adjust the electrolyte
levels in nickel-cadnium cells. A very small quantity of acid is sufficient to
cause permanent damage.
For this operation, use plastic syringe with a plastic nozzle (T03) (refer to SPECIAL TOOLS,
FIXTURES AND EQUIPMENT). The length of the nozzle is 20 mm (0.79 in). This is the distance necessary between the seat of the vent valve and the electrolyte (Refer to figure 5002).
10
5
(2)
20 mm
Level adjustment with a syringe and calibrated nozzle
Figure 5002/TASK 24-38-53-991-011
To adjust the level, keep the shoulder of the syringe nozzle against the seat of the vent valve
and pull the plunger up.
If the level is not sufficient, the syringe tube stays empty when you pull the plunger. Add distilled water to these cells. (The syringe is small, it can thus be necessary to do this step more
than one time for each cell).
If there is too much liquid, this liquid is removed by the syringe until the level aligns with the
end of the nozzle.The level is correct when only a small quantity of liquid goes into the syringe
when you pull the plunger.
Also, write down the quantity of distilled water added to each cell
24-38-53
Page 5004
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
(3) Vent valve cleaning
Clean the vent valve (190) (Refer to "CLEANING" chapter) when you adjust the electrolyte levels.
(4) Nut tightness
Make sure that all the nuts that attach the links are torqued (refer to the chapter FITS
AND CLEARANCES).
(5) Results of the above procedures
(a) The battery operates correctly if:
- The voltage of each cell measured during the last hour of charge at 4 A is not less than
1.55 V.
- Approximately the same quantity of distilled water is added to each cell. This quantity
must be less than 60 cm3 (3.66 in3).
NOTE : If the average quantity of wat er added to all the cells is close to 60 cm3/cell
(3.66 in3/cell), do the electrolyte level check more frequently.
(b) Do a full overhaul of the battery (refer to PARA D "General overhaul") if:
- the quantity of water necessary for one or more cell(s) is much higher or smaller than
for the other cells.
- the voltage of each cell measured at the end of a 4 A charge is less than 1.55 V (refer
to the chapter TESTING AND FAULT ISOLATION).
24-38-53
Page 5005
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
SUBTASK 24-38-53-210-002
C. Regular check (Ref Fig. 5003)
At least every 3000 operating hours and BEFORE A MAXIMUM OF ONE YEAR, do this battery
test according to Fig 5003.
NOTE : According to aicraft operati on, the ratio betw een op erating hou rs (aircraft
"power on") and flying hours is generally in the 1.2 to 1.8 range.
(1) Measurement of the voltage
Measure the voltage in open circuit at the terminal of the battery. If Ubat < 21 V, then do the
polarization test.
(2) Residual discharge
Discharge the remaining capacity at 40 A down to a voltage of 20 V at the battery terminals.
Measure the time from the start of discharge to the time when the voltage reaches 20 V.
(3) 1 Ω cell shorting
Connect a resistor approximately 1 Ω 3 W (T03) across each cell and continue to discharge.
Resistors with crocodile clips attached to their leads can easily be attached to the cell terminals. Keep the resistors in position for 12 hours. Remove all resistors.
(4) Charge the battery
Refer to PARA B (1) "Periodical Check"
(5) Adjustment of electrolyte
Refer to PARA B (2) "Periodical Check"
(6) Capacity check
Immediately after the charge and the level adjustment, discharge the battery again at 40 A.
At 1 hour of discharge, measure the voltage of each cell. This voltage must be over 1 V. Continue to discharge the battery down to 20 V. Write the time necessary for the second discharge.
(7) Vent valve cleaning
Refer to PARA B (3) "Periodical Check"
24-38-53
Page 5006
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
REGULAR CHECK 2.C
no
Insulation check
> 2 MΩ
yes
Remove the cover
yes
Light cleaning
yes
dust only?
no
Salt or electrolyte traces
Nut tightness
Supplementary test
OK?
yes
Add 5 h overcharge
U > 1.55 V
Adjust electrolyte
POLARIZATION TEST
1 Ω cell shorting
overnight
Charge
no
Cell voltage before
end of charge
U > 1.55 V
Adjustment of electrolyte level before
end of charge
(volume < 60 cm3)
Dispersion < 30 %
FAULT ISOLATION
no
no
General overhaul
figure 5004
with replacement of
faulty components .
If more than 5* original
cells, then change all
cells.
no
Residual discharge
1 V/cell
General overhaul
figure 5004
FAULT ISOLATION
U > 21 V
no cell with reversed
polarity
Supplementary test
OK?
Completed charge
Add 5 h overcharge
no
U > 1.55 V
Adjust electrolyte
level.
Discharge > 1 h.
yes
Capacity check
1 V/cell ≥ 1 h
yes
Vent valve cleaning
yes
* If 3 or more cells changed during the same check, change all cells.
Nut tightness
Charge
Battery accepted after
regular check
Regular check
Figure 5003/TASK 24-38-53-991-012
24-38-53
Page 5007
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
(8) Results of the above tests:
(a) The battery operates correctly if:
- The time necessary for the first discharge is more than 30 minutes.
- The time necessary for the second discharge is not less than 1 hour.
- The voltage of each cell measured during the last hour of the charge at 4 A is not less
than 1.55 V.
- The variation of water consumption in individual cell does not exceed ±30% of the average consumption for all cells.The maximum limit is 60 cm3 (3.66 in3).
NOTE : If the average quantity of wat er added to all the cells is close to 60 cm3/cell
(3.66 in3/cell), do the electrolyte level check more frequently.
- If the first discharge time is less than 30 minutes but the second discharge time is correct: the battery is in good condition but was not fully charged when removed from the
aircraft. This condition can be caused by an incorrect charge in the aircraft and/or a discharge caused by an unusual operation of the battery after landing.
(b) Do a full overhaul of the battery if:
- the quantity of water necessary for one or more cell(s) is much higher or smaller than
for the other cells.
- the voltage of each cell measured at the end of a 4 A charge is less than 1.55 V (refer
to the chapter TESTING AND FAULT ISOLATION).
- The second discharge time is less the correct one or one cell has a voltage of less than
1 V (or incorrect polarity before 1 hour of discharge).
NOTE : The decrease of water in a c ell is in proportion to the over charge. Thus, the
decrease should be the same for all 20 cells in the battery.
If the quantity of water necessary for one or more cell(s) (in the same battery) is much
higher (or smaller) than the other cells. This means that there is a defect:
- Leakage usually causes heavy decrease.
- A damaged separator causes low decrease.
24-38-53
Page 5008
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
SUBTASK 24-38-53-210-003
D. General overhaul (minimum 1 per year)
This overhaul includes electrical tests. It also includes disassembly and cleaning procedures to
do systematically for all battery components. Do this battery test according to Fig 5004
(1) Disassembly
Refer to "DISASSEMBLY" chapter.
(2) Thorough cleaning
Refer to "CLEANING" chapter.
(3) Do a battery inspection.
(a) Cells
Verify that cell boxes show no leakage.
NOTE : If more than 5 original cells have been changed or more than 3 cells are
faulty in the same maintenance, then change all cells.
Any cells that are to be changed must be replaced by a new Saft original
cell.
(b) Box
Make the sides of the box straight and remove dents (Refer to "REPAIR" chapter).
(c) Nuts, links and spring washers
Discard the components that show signs of corrosion or damage.
(d) Liner and spacers
Discard all defective components.
(e) Connector
Make sure that the connector is in good condition (inner and outer surfaces). Replace it
if contacts are burned.
(4) Insulation check
Refer to PARA E. (Insulation check)
24-38-53
Page 5009
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
(5) Charge the battery
Refer to PARA B (1) "Periodical Check"
(6) Adjustment of electrolyte
Refer to PARA B (2) "Periodical Check"
(7) Capacity check
Refer to PARA C (6) "Regular Check"
(8) Vent valve cleaning
Refer to PARA B (3) "Periodical Check"
(9) Assembly
Refer to chapter "Assembly" page block 7000.
24-38-53
Page 5010
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
GENERAL OVERHAUL 2.D
Scheduled
yes
U > 21 V
no cell with reversed polarity
On fault
no
POLARIZATION TEST
Nut tightness
Residual discharge
1 Ω cell shorting
overnight
Disassembly
Thorough cleaning
Component inspection
Faulty component
replacement
Charge
Assembly
no
Insulation check
> 10 MΩ
no
yes
FAULT ISOLATION
Supplementary
test OK?
no
Add 5 h overcharge U > 1.55 V
Cell voltage before
end of charge
U > 1.55 V
yes
Adjustment of electrolyte level before end of
charge
(volume < 60 cm3)
Dispersion < 30 %
yes
FAULT ISOLATION
General overhaul
with replacement of
faulty components .
If more than 5* original
cells then change all
cells.
* If 3 or more cells changed during
the same check, change all cells.
Supplementary test
OK?
Completed charge
Add 5 h overcharge
U > 1.55 V
no
Adjust electrolyte
level. Discharge
> 1 h.
no
Capacity check
1 V/cell ≥ 1 h
yes
Vent valve cleaning
Nut tightness
yes
Charge
Battery accepted after general overhaul
General overhaul
Figure 5004/TASK 24-38-53-991-013
24-38-53
Page 5011
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
NOTE: If more than 5 original cells have been changed or more than 3 cells are faulty in the
same maintenance, then change all cells.
SUBTASK 24-38-53-280-001
E. Insulation check
Refer to the chapter TESTING AND FAULT ISOLATION .
24-38-53
Page 5012
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
REPAIR
1. General
As the CHECK chapter indicates, defective parts for which no repair instructions are given shall be
rejected and replaced by new parts.
The figure and item numbers used in this chapter agree with those of the ILLUSTRATED PARTS
LIST.
2. Equipment
A. Special tools
When special tools are used in this chapter, they are identified by a code number listed in the
chapter SPECIAL TOOLS, FIXTURES AND EQUIPMENT.
B. Standard tools
Standard mechanic’s tools.
3. Repairs
The only authorized repair applicable to the unit is:
- Changing a gasket cover (040).
24-38-53
Page 6001
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
REPAIR N°1
TASK 24-38-53-900-801
1. Changing a cover gasket
A. General
You can change the gasket cover (040) only one time.
B. Detailed procedure
- Remove the gasket cover (040).
- Clean the joint location.
- Apply paste to the flat side of the gasket
- Let stay dry for 2 hours in a dry place.
- Put gasket on the bottom of the cover (030). Press firmly.
24-38-53
Page 6002
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
ASSEMBLY
1. General
You can assemble parts on a clean workbench in a clean, dry room. They will be protected from hit
damage.
For tightening parts refer to the torque table in the chapter FITS AND CLEARANCES .
Make sure that the storage protection layer is removed from the new part before assembly.
The figure and item numbers used in this chapter agree with those of the ILLUSTRATED PARTS
LIST.
To do check points, refer to CHECK chapter.
TASK 24-38-53-400-801
2. Assembly procedure
A. Equipment
(1) Special tools
When special tools are used in this chapter they are identified by a code number listed in the
chapter SPECIAL TOOLS, FIXTURES AND EQUIPMENT.
(2) Standard tools
- Standard mechanic’s tools.
- Safety gloves.
- Protectives goggles.
- Safety shoes.
- Eye wash.
- Protective apron.
24-38-53
Page 7001
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
SUBTASK 24-38-53-420-001
B. Installation of the liner spacer kit (200) (Ref. Fig. 7001)
(1) Put in position the E and F spacers.
(2) Put in position the A, B, C and D side spacers.
(3) Put in position the G, H and I side spacers.
(4) Install the cell in the two end spacers.
CAUTION: The A and B slotted spacers will be assembled so as to keep the ventilating system of the box free.
A
Spacer slotted
1x245x232
2
B
Insulator slotted
0.5x245x232
4
C
Spacer
2x232x65
5
D
Spacer
1x232x65
12
E
Insulator
1x249x80
2
F
Insulator
1x249x80
1
G
Spacer
1x220x75
1
H
Insulator
0.5x245x220
2
I
Spacer
1x220x210
2
24-38-53
Page 7002
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
Liner spacer kit installation
Figure 7001/TASK 24-38-53-991-013
24-38-53
Page 7003
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
SUBTASK 24-38-53-420-002
C. Installation of the vent valve (190)
(1) Make sure the vent valves (190) are in good condition. Replace the vent valves (190) if they
are worn.
(2) Install the vent valve (190) with the special tool (T01). Hold the special tool by its upper ribbed
part.
SUBTASK 24-38-53-420-003
D. Installation of a cell (Ref. Fig. 7002)
(1) Put five cells (130) in the side compartments.
(2) Put four cells (130) in the middle of each compartment.
(3) Move the last cell into position (if it is difficult to put in the last cell, remove one or two spacers).
(4) Carefully position the cell (130) and push onto terminals with a piece of soft wood.
(5) Install the links (080 thru 110).
(6) Install the spring washers (070).
(7) Install the nuts (060) and torque them.
(8) Lightly lubricate the terminals and the links with neutral petrolatum or light oil (use a paintbrush).
(9) Install the cover (020) and attach it.
SUBTASK 24-38-53-970-001
E. Inform
(1) Identification plate (270) if the box (250) has been changed.
(2) Log book.
24-38-53
Page 7004
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
110
090
080
100
Cell installation
Figure 7002/TASK 24-38-53-991-014
24-38-53
Page 7005
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
PAGE INTENTIONALLY LEFT BLANK
24-38-53
Page 7006
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
FITS AND CLEARANCES
TASK 24-38-53-400-802
1. Torque table
SUBTASK 24-38-53-420-001
A. Torque table
List of all applicable torque values necessary to assemble and do servicing of the battery:
NOTE: The values here are "lube torque" values. You must lightly apply grease on the
threads before to installation and applying torque.
IPL
FIG ITEM
N°
TORQUE VALUE
NAME
N.m
lbf.in
060
Nut
12 to 14
106 to 124
140
Nut
4.5 to 5.5
40 to 49
24-38-53
Page 8001
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
PAGE INTENTIONALLY LEFT BLANK
24-38-53
Page 8002
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1. General
This chapter is divided into two parts:
- The first part provides the list of SPECIAL TOOLS, AND FIXTURES AND EQUIPMENT necessary
to perform the steps listed in the order chapters.
- The second part provides the listing of Consumable Materials used in this manual.
All listed items are identified in this manual by a standard code number:
- Txx for TOOLS, FIXTURES AND EQUIPMENT,
- Mxx for Consumable Materials.
2. Special tools, fixtures and equipment
CODE
QTY
PART
NUMBER
DESCRIPTION
USE
T01
1
046002
Polyamide key for polyamide
vent valve
DISASSEMBLY - CLEANING CHECK - ASSEMBLY
T02
1
104184
Syringe assembly (with nozzle)
TESTING AND FAULT ISOLATION - CHECK
T03
1
164829
Equalizing resistors
(1 Ω / 3 W)
TESTING - CHECK
T04
1
013169
Cell extraction tool
DISASSEMBLY
24-38-53
Page 9001
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
Polyamide key for vent valve (T01)
Figure 9001/TASK 24-38-53-991-015
Syringe with nozzle (T02)
Figure 9002/TASK 24-38-53-991-016
24-38-53
Page 9002
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
Equalizing resistor (T03)
Figure 9003/TASK 24-38-53-991-017
24-38-53
Page 9003
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
Cell extraction tool (T04)
Figure 9004/TASK 24-38-53-991-018
24-38-53
Page 9004
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
3. Consumables
NOTE: Equivalent alternatives can be used for list items.
DESIGNATION
PART NUMBER
AND
SPECIFICATION
MANUFACTURER
OR SUPPLIER
(NAME,
ADDRESS, CODE)
A
I
R
L
I
N
E
S
T
E
S
T
C
O
D
E
Distilled or deionized water
clear, colorless, oderless while
boiling, resistivity > 30 kΩ/cm
5 < pH < 7
Absence of organic and reducing substances. Reducing
agent content (expressed in
weight of oxygen) < 30 mg/l
(test with permanganate).
Total of ions
SO42+ Cl- < 10 mg/l
Dry abstract < 15 mg/l
Silicium in SiO2 < 15 mg/l
Local vendor
Soap
Local vendor
Neoprene glue
Local vendor
Mineral vaseline
OTAN: S 743
F: AIR 3565
US: VLP 236
UK: DEF 2333
X
D
I
S
A
S
S
E
M
B
L
Y
C
H
E
C
K
C
L
E
A
N
I
N
G
R
E
P
A
I
R
A
S
S
E
M
B
L
Y
S
T
O
R
A
G
E
X
X
X
X
X
CAUTION: Use only distilled or deionized water.
24-38-53
Page 9005
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
PAGE INTENTIONALLY LEFT BLANK
24-38-53
Page 9006
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
ILLUSTRATED PARTS LIST
24-38-53
TP Page 10001
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
PAGE INTENTIONALLY LEFT BLANK
24-38-53
TP Page 10002
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
INTRODUCTION
1. Introduction
A. General
The Illustrated Parts List (IPL) contains a list and illustrations of the assemblies and detailed parts
of the unit in disassembly sequence.
It includes the following sections :
- Introduction (INTRO),
- Numerical Index (NI),
- Detailed Parts List (DPL).
B. How to Use the illustrated Parts List
(1) To find the illustration for a part if the part number is known, refer to the Numerical Index and
look for the part number and the corresponding figure and item number. Refer to the Detailed
Parts List and look for the first figure and item number found in the Numerical Index for that
part. If this figure shows the part in a section or system of the equipment other than the one
necessary, refer to the other figure numbers listed in the Numerical Index.
(2) To determine the part number of a given part, refer to the illustration showing the assembly
including this part. Note the item number of the illustrated part and refer to the Detailed Parts
List which indicates its part number and identification.
2. Equipment Designator Index (EDI)
The Equipment Designator Index provides all circuit symbols given to the electrical and electronic
components of the items listed in alphanumeric order for the letters, numerical order for the figures.
24-38-53
Page 10003
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
3. Numerical Index (NI)
In this index, part numbers are classified in the following order:
Classification is made from left to right, each character (letter, number, hyphen) being considered
separately.
The first left row ordering is :
- hyphen
- alpha letter from A to Z (except for " O " and " I " to be considered as zero and one)
- numbers from 0 to 9.
The part number column contains all part numbers included in the Detailed Parts List. Part numbers
that have been deleted or superseded within the Detailed Part List are listed in the Numerical Index
and identified as deleted or superseded.
4. Detailed Parts List (DPL)
A. Figure and Item Number
Each assembly, sub-assembly and part holding a part number and included in the parts list is given a time number.
The figure number linked to the item number is shown on the first line at the top of each page.
Assemblies, sub-assemblies and numbered parts included in the list but not illustrated are identified by a hyphen (-) preceding the item number.
An index letter shown before the item number refers to the figure showing the modified portion of
the applicable part.
B. Manufacturer's Part Number
A manufacturer's part number is given to each assembly and detail part, whether illustrated or not.
24-38-53
Page 10004
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
C. Parts List
The parts list is represented with indenting showing the relationship of parts and assemblies to
their next higher assemblies as follows :
1234567
Assembly
. Detailed parts for assembly,
. Sub-assembly
Attaching parts and/or storage parts for sub-assembly,
***
. . Detailed parts for sub-assembly
. . Sub-sub-assembly,
Attaching parts and/or storage parts for sub-sub-assembly,
***
. . . Detailed parts for sub-sub-assembly.
The attaching parts are shown directly after the assembly of the part thereof. They are listed under
the same indent number as the item they are attached to, and are identified by the words "Attaching Parts" and are followed by three asterisks.
The manufacturer's code or the abbreviation NP (not procurable) are placed at the extreme righthand side of the first line of the parts list column.
D. Effectivity code
An alphanumerical index indicates the effectivity of sub-assemblies and detailed parts lists in relation to the next higher assembly (ies) or sub-assembly (ies).
When the effectivity is fully applicable, the usage code column remains blank.
The usage code for assemblies and detailed parts refers to the figure/item number of the next
higher assembly (ies) or sub-assembly (ies).
Example : Effectivity 1A, 1B, 1C is written 1ABC.
24-38-53
Page 10005
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
E. Units per Assembly
The units per assembly column showns the quantity of units required for one next higher assembly.
In some cases, the information is replaced by the abbreviation RF (for reference) or AR (as required).
24-38-53
Page 10006
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
5. Abbreviation used
ALT FROM PN XXX
AMDT
AR
DELETED
DET
DPL
EDI
IPL
LH
MFR
MODIFIED FROM
NHA
NP
OLD PN
OPT PN
OPT SEE TABLE
ORDER OVRLGTH MPN
OVERSIZE
PN
POST SB
PRE SB
R
RF
RH
SEE CMM
SEE FIG FOR DET
SEE FIG FOR NHA
SEL FROM
SUPSD BY
SUPSDS
UNDERSIZE
VL
Part that is functionally and physically interchangeable with original part
after reworking.
Amendment
As required
Deleted part
Detail
Detailed Parts List
Equipment Designator Index
Illustrated Parts List
Left hand
Manufacturer or Optional Manufacturer in the IPL
Part obtained by modifying another part
Next higher assembly
Not procurable
Old part number. This item has never been installed.
Optional part number that is fully interchangeable with the part in the
part number column.
See optional table
Part number over fifteen characters
Part with size exceeding its nominal dimension.
Part number.
After modification brought up by a Service Bulletin.
Before modification brought up by a Service Bulletin.
Modified
For reference.
Right hand.
See component Maintenance Manual.
See figure for details.
See figure for next higher assembly.
Selected from. Part which is to be selected as necessary from collection of parts.
Superseded by XXX.
Supersedes XXX.
Part with size smaller than its nominal dimension.
Vendors List.
24-38-53
Page 10007
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
6. Updating
A. General
When an item is revised, added or deleted, the letter " R " is shown in the right-hand margin (the
date of issue changes).
B. Added items
The basic sequence of the items given from 10 to 10 makes it possible to add new items between
the old ones in the appropriate order of the breakdown. With the addition of more than nine new
items, a new number is to be added at the end of the IPL.
C. Deleted items
Should a part number definitively deleted, the information given in the parts list zone is deleted.
The old part number always remains in the numerical index.
D. New Figure Number Added
Whenever new illustrations are necessary the alternative figures are inserted. They refer to the
same parts list.
The alternative figure is given with the basic figure number and letter. This letter precedes the item
number in the parts list.
24-38-53
Page 10008
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
VENDOR CODE INDEX
VENDOR CODE
NAME-ADDRESS
F6177
SAFT
12, Rue Sadi Carnot
93170 BAGNOLET
Telex - 235566 F
Phone: (33) (01) 49 93 19 18
Fax: (33) (01) 49 93 19 58
V09052
SAFT AMERICA INC.
711 Industrial Boulevard
Valdosta, GA 31601
USA
Phone: (1) 229 247 2331
Fax: (1) 229 247 8486
24-38-53
Page 10009
Sep 30/2005
COMPONENT MAINTENANCE MANUAL
405CH
PAGE INTENTIONALLY LEFT BLANK
24-38-53
Page 10010
Sep 30/2005
COMPONENT MAINTENANCE MANUAL
405CH
ALPHA NUMERICAL INDEX
PART NUMBER
405 CH
012374
015266
015539
062007
062007
100078
100094
100094
100094
100430
100431
100693
100694
102392
117026
117704
166309
166314
411108
411691
412479
412619
413597
413600
413607
413609
413714
413765
413791
414030
414362
415059
AIRLINE
STOCK NUMBER
FIG
NUMBER
INDEX
NUMBER
TOTAL
REQUIRED
01
-001
080
100
090
060
140
180
070
120
170
220
210
160
150
230
260
320
280
330
270
110
030
050
130
190
300
290
200
040
020
250
010
240
PM
15
1
2
42
2
2
42
40
2
4
4
1
1
1
1
1
2
1
1
3
1
2
20
1
2
2
1
1
1
1
1
1
- Item not illustrated.
24-38-53
Page 10011
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
PAGE INTENTIONALLY LEFT BLANK
24-38-53
Page 10012
COMPONENT MAINTENANCE MANUAL
405CH
DETAILED PARTS LIST
110
080
090
100
060
070
140
150
170
180
190
160
280
040
030
020
130
200
250 (010 with cover 020
and handle 050)
060
070
310
230
280
220
210
240 260
270
290
050
300
405CH BATTERY
Figure 1/GRAPHIC 24-38-53-991-19
24-38-53
Page 10001-0
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
FIGURE
AND
ITEM
PART
NUMBER
AIRLINE
STOCK
NUMBER
NOMENCLATURE
1234567
EFF.
CODE
UNITS
PER
ASSY
01
-001
-010
020
030
040
050
060
070
080
090
100
110
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
310
405CH
414362
413791
412479
413765
412619
062007
100094
012374
015539
015266
411691
413597
062007
100694
100693
100094
100078
413600
413714
100431
100430
102392
415059
414030
117026
411108
166309
413609
413607
280068
Battery 405CH, CVH 400 KA
. Box and cover complete
. Cover complete
. . Cover, assembly
. . Gasket, cover
. Handle, strap
. Nut M10X1.25
. Washer, spring
. Link, intercell, E34
. Link, intercell, E37
. Link, intercell, E49
. Link, intercell, curved
. Cell, CVH 400KA, assembly
. . Nut M10X1.25
. . Washer, positive polarity
. . Washer, negative polarity
. . Washer, spring
. . Washer, flat
. . Vent valve
. Liner-spacer kit
. Screw M4X10
. Washer, lock
. Connector complete
. Protector
. Box assembly
. Film, protector
. Plate, identification
. Plate, filling instruction
. Plate, SAFT label
. Plate, range label
. Plate, recycling
PM
1
1
1
1
2
42
42
15
2
1
3
20
2
1
1
2
2
1
1
4
4
1
1
1
1
1
2
2
2
1
- Item not illustrated.
24-38-53
Page 10001-1
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
STORAGE (INCLUDING TRANSPORTATION)
TASK 24-38-52-600-802
1. Storage
A. Preparation of the battery before storage
- Adjust the electrolyte levels (Refer to "CHECK"), then discharge at a constant current of 40 A
down to 20 V.
- Lightly lubricate these components with neutral petrolatum or light oil: the nuts, the links, the
connector contacts and all the components that can be damaged by atmospheric corrosion.
- Put the battery in its usual vertical position.
B. Storage room
Keep the batteries and spares in a dry and clean room.
C. Temperature conditions
The recommanded temperature range is + 20 °C ± 15 °C (68 °F ± 27 °F). However, occasional
excursions into the range of - 60 °C to + 60 °C (- 76 °F to + 140 °F) is permitted.
D. Packing
The batteries are usually put in cardboard boxes. For long storage or sea transportation, we recommendto put the batteries in a welded plastic container. In this type of container, with the recommanded temperature range, the batteries can be kept for 10 years.
TASK 24-38-52-600-803
2. Storage procedure
A. General
When the battery arrives in the battery shop for servicing:
- Visual inspection: if dust or salt do a General Overhaul according procedure (refer to CHECK
chapter).
- Then light cleaning (refer to CLEANING chapter), then service as scheduled (periodical check,
regular check or general check) (refer to CHECK chapter).
24-38-53
Page 15001
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
SUBTASK 24-38-52-610-001
B. Short term storage (Ref. Fig. 15001)
(1) Operations
- Place the charged battery (serviced according to CMM procedure) in a cool room or discharge to 1 V/cell (refer TESTING AND FAULT ISOLATION chapter).
- Light greasing of cells terminals.
- Place in a storage room.
24-38-53
Page 15002
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
100
AVAILABLE CAPACITY (%C1Ah)
CHARGE RETENTION
Aircraft Ni-Cd battery
90
5 °C
20 °C
80
25 °C
30 °C
70
35 °C
40 °C
60
0
10
20
30
40
50
60
REST TIME (days)
70
80
90
Short term storage
Figure 15001/TASK 24-38-53-991-020
24-38-53
Page 15003
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
SUBTASK 24-38-52-610-002
C. Long term storage
(1) Operations
- Discharge to 1 V/cell.
- Light greasing of cells terminals.
- Place in a storage room.
(2) Conditions
The battery should be stored filled and discharged.
The storage life is 10 years, if using the following conditions :
- Sealed packaging.
- Temperature: + 20 °C ± 15 °C (68 °F ± 27 °F).
- Humidity: < 70 %.
- Normal vertical position.
- Isolated from detrimental agents : Le. dirt, dust, clampness, vibration, corrosive atmosphere.
NOTE : Lead batteries must be stored in a different room.
CAUTION : Saft Ni-Cd batteries may be stored in temperatures ranging from -60 °C (- 67 °F)
to + 60 °C (+ 140 °F) for short periods of time without harming the battery.
The standard cardboard packaging is considered unsealed and allows 2 years
of storage under the above conditions.
No maintenance operation needs to be performed during the storage period.
24-38-53
Page 15004
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
TASK 24-38-52-600-804
3. Servicing after storage
Storage time
Servicing procedure
Less than 3 months
Charge the battery (Do one of the procedures given in "TESTING
AND FAULT ISOLATION" chapter) for a fully discharged battery.
3 months to 1 year
Do the Periodical check (refer to "CHECK" chapter).
More 1 year
Do the Regular check (refer to "CHECK" chapter).
TASK 24-38-52-500-801
4. Transportation
The battery must be discharged before packing.
The battery should then be packed vertically in its original container. If the original container is not
available, the international and/or local packaging regulations applicable to the mode of transport
and destination must be followed.
24-38-53
Page 15005
Jul 01/2008
COMPONENT MAINTENANCE MANUAL
405CH
PAGE INTENTIONALLY LEFT BLANK
24-38-53
Page 15006
Jul 01/2008