24-32-11 COMPONENT MAINTENANCE MANUAL WITH

SAFT
711 INDUSTRIAL BOULEVARD
VALDOSTA, GEORGIA 31601
COMPONENT MAINTENANCE MANUAL
WITH
ILLUSTRATED PARTS LIST
Nickel Cadmium Battery
MODEL NO. 5347CH1
Part No. 024797-000
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COMPONENT MAINTENANCE MANUAL
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RECORD OF REVISIONS
REV ISSUE
NO. DATE
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DATE
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REV
NO.
ISSUE
DATE
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DATE
BY
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RECORD OF TEMPORARY REVISIONS
TEMPORARY
REV NO
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NUMBER
ISSUE DATE
BY
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DATE
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COMPONENT MAINTENANCE MANUAL
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SERVICE BULLETIN LIST
SERVICE BULLETIN
NUMBER
REVISION NUMBER
DATE BULLETIN
INCORPORATED INTO
MANUAL
PRODUCT IMPROVEMENTS
Product Improvements have been incorporated using service bulletins entered in the
service bulletin list. Service bulletin highlights are as follows:
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COMPONENT MAINTENANCE MANUAL
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LIST OF EFFECTIVE PAGES
SUBJECT
PAGE
DATE
SUBJECT
PAGE
DATE
Title Page
T-1
T-2
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Disassembly
301
302
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Record of Revisions
RR-1
RR-2
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Blank
Cleaning
Record of Temporary
Revisions
RTR-1
RTR-2
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Blank
401
402
403
404
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Mar 15/99
Mar 15/99
Blank
Check
Service Bulletin List
SBL-1
SBL-2
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Blank
List of Effective Pages
LEP-1
LEP-2
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Blank
Table of Contents
TC-1
TC-2
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501
502
503
504
505
506
507
508
509
510
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Introduction
INTRO-1
INTRO-2
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Repair
601
602
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Description and
Operation
1
2
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Assembly
Testing and Fault
Isolation
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
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701
702
703
704
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Fits and Clearances
801
802
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Special Tools,
Fixtures, and
Equipment
901
902
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Illustrated Parts List
1001
1002
1003
1004
1005
1006
1007
1008
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TABLE OF CONTENTS
PARAGRAPH TITLE
PAGE
Description and Operation
1
Testing and Fault Isolation
101
Automatic Test Requirements (ATLAS)
N/A
Disassembly
301
Cleaning
401
Check
501
Repair
601
Assembly (Including Storage)
701
Fits and Clearances
801
Special Tools, Fixtures, and Equipment
901
Illustrated Parts List
1001
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COMPONENT MAINTENANCE MANUAL
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INTRODUCTION
The instructions in this manual provide the information necessary for an experienced shop
technician to perform shop type repair.
The manual is divided into separate sections:
1.
Title Page
2.
Record of Revisions
3
Record of Temporary Revisions
4.
List of Effective Pages
5.
Table of Contents
6.
Introduction
7.
Procedures and IPL Sections
The Disassembly, REPAIR, and Assembly sections generally contain only specific
instructions to be used on the equipment covered herein. Most standard aerospace
practices are not described in this manual.
An explanation of the use of the Illustrated Parts List (IPL) is provided in the Introduction to
that section.
Every effort has been taken to provide complete and accurate component maintenance
instructions. However, if a situation should arise that is not adequately covered by this
manual, please contact Saft at one of the following addresses:
Saft
711 Industrial Boulevard
Valdosta, Georgia 31601
Saft
156 Avenue de Metz
93230 Romainville, France
Telephone:
FAX:
Telephone:
FAX:
(912) 247-2331
(912) 247-8486
33 1 49 15 36 00
33 1 49 42 91 15
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COMPONENT MAINTENANCE MANUAL
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DESCRIPTION AND OPERATION
1.
Description
The 5347CH1 is a nickel-cadmium type with sintered and plastic bonded electrode
plate construction, and uses a potassium hydroxide electrolyte. The battery consists
of a case and cover, 20 cell assemblies, and a temperature sensor harness
assembly.
2.
Operation
The battery is charged on the aircraft by the electrical system. The temperature
sensor harness assembly provides a signal to the cockpit to indicate the battery
temperature. The thermostat will cut off the charger if the battery temperature has
exceeded a safe operating limit.
Voltage:
Nominal
Open Circuit Voltage, fully charged
Weight
Dimensions (Maximum):
Height
Length (Base)
Width (Base)
Cell Assembly Terminal
Number of Cell Assemblies
Cell Model
Cell Maximum Consumable Electrolyte
Rated Capacity
End of Life Capacity
Venting Pressure
Cell Assembly Case Material
Battery Case Material
Electrolyte
24 Volts
31 Volts
89.3 lb. (40.59 kg)
10.50” (266.70 mm)
9.76” (247.90 mm)
11.05” (280.67 mm)
M10 x1.25
20
CVH 530 KA
78 cm3
53 Ah (1 hour rate)
53 Ah (1 hour rate)
2 to 10 psi (0.14 to 0.7 bar)
Polyamide
Stainless Steel
Potassium Hydroxide
Leading Particulars
Figure 2
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COMPONENT MAINTENANCE MANUAL
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TESTING AND FAULT ISOLATION
1.
General
This section contains battery functional tests and fault isolation information. Test
procedures are written in a step-by-step format. Fault isolation information is
presented in chart form.
NOTE:
2.
All ( ) part identification numbers herein are IPL Fig. 1 item numbers.
Required Test Equipment
Figure 101 covers the electrical test equipment that may be needed during
maintenance in addition to the items contained in the Battery Maintenance Kit
(P/N 024629-000) (refer to SPECIAL TOOLS, FIXTURES AND EQUIPMENT).
NOTE:
Test equipment having equivalent specifications can be used.
NOMENCLATURE
APPLICATION
DC Power Supply, regulated,
35 Vdc 60 A minimum
Testing / Fault Isolation
Precision Multimeter
(precision +0.5%),
0-2 V, 0-5 V, and 0-50 V scales
required
Testing / Fault Isolation
DC Load Bank
0-60 A
Testing / Fault Isolation
Thermometer, Immersion
Testing / Fault Isolation
Megohmmeter 250 Vdc
Testing / Fault Isolation
(analog)
Required Test Equipment
Figure 101
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COMPONENT MAINTENANCE MANUAL
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3.
Testing
A.
Test Conditions
(1)
(2)
B.
Facilities and equipment
(a)
Service facilities for Ni-Cd batteries must be entirely separate
from those for lead acid batteries. Fumes from lead acid
batteries or small traces of sulfuric acid entering a Ni-Cd battery
can cause permanent damage.
(b)
Equipment used to service lead acid batteries must not be used
to maintain Ni-Cd batteries.
For optimum results, conduct all tests with the battery temperature at
77°F (25°C).
Test Equipment
Refer to Special Tools, Fixtures, and Equipment for a list of test equipment
required for proper maintenance of a Ni-Cd battery.
C.
Initial Discharge
The purpose of this discharge procedure is to bring the battery to a known
state of charge; i.e. 1.0 volt per cell.
(1)
Discharge the battery at one of the rates listed in Fig 102 until each cell
in the battery reaches 1.0 V.
NOTE:
If it is desired to perform a capacity check, refer to the
procedures found under Second Discharge in this
section.
NOTE:
It is not a cause for concern if a cell goes to zero volts or
reverses polarity during the discharge. Simply short the
terminals of that cell for the remainder of the discharge.
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Constant Current
Discharge Rate
Discharge Time
(For capacity check)
53 Amps
26.5 Amps
60 Minutes
122 Minutes
Discharge Rates
Figure 102
D.
Residual Discharge
The Residual Discharge is designed to drain all electrical energy from the
battery. This is typically referred to as the “deep cycle”.
(1)
Discharge each cell in the battery to zero volts using one of the
following two procedures.
NOTE:
(2)
It is not necessary to have a rest period between
discharge and residual discharge.
(a)
Continue to discharge the battery. After battery voltage drops to
<1.0 V, connect a 1.0 ohm (3.0 watt minimum) shorting resistor
across each cell’s terminals. Leave the resistor in place for 12
to 16 hours to allow each cell to completely discharge and the
battery to cool. The resistors should be fitted with alligator clips
to ensure a firm connection (see Fig 103).
(b)
Continue to discharge the battery. After battery voltage drops to
<10 V, insert a shorting clip between the main battery connector
terminals. Leave this clip on for 12 to 16 hours to allow all cells
to completely discharge and the battery to cool.
Remove the shorting devices before charging.
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Shorting Clip (1Ω - 3 Watt Minimum)
Figure 103
E.
Charge
CAUTION:
ATTEMPTING TO CHARGE BATTERIES WITH LOW
ELECTROLYTE LEVELS IN ANY CELL MAY CAUSE
PERMANENT DAMAGE TO THAT CELL.
(1)
Remove the cover and pad assembly.
(2)
Loosen, but do not remove, all vent valves.
NOTE:
Check individual cell voltages at the beginning of the
charge. If any cell indicates an immediate voltage rise
above 1.55 V, add about 10 cm3 of distilled or
demineralized water through the vent valve opening of
that cell.
(3)
Charge using one of the methods shown in Fig. 104.
(4)
During the last 15 minutes of the overcharge cycle, adjust the
electrolyte level (see Electrolyte Level Adjustment - Sect J).
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COMPONENT MAINTENANCE MANUAL
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CONSTANT CURRENT CHARGE
Main Charge
Overcharge
Overcharge at 5.3 Amps
Method 1: 5.3 Amps (0.1C1A) until battery
(0.1C1A) for 4 hours after
reaches 31 V
main charge with all cells
Time:
Minimum:
10 hours
≥1.55 V. Total charge not to
Maximum:
12 hours
exceed 16 hrs.
OR
Method 2: 26.5 Amps (0.5C1A) until battery Overcharge at 5.3 Amps
(0.1C1A) for 4 hours after
reaches 31.4 V
main charge with all cells
Time:
Minimum:
2 hours
≥1.55 V. Total charge not to
Maximum:
2 hours 30 min.
exceed 6.5 hours.
OR
Overcharge at 5.3 Amps
Method 3: 53 Amps (1C1A) until battery
(0.1C1A) for 4 hours after
reaches 31.6 V
main charge with all cells
Time:
Minimum:
1 hour
≥1.55 V. Total charge not to
Maximum:
1 hour 15 min.
exceed 5.25 hours.
Charge Rates
Figure 104
F.
Second Discharge (Capacity Test)
The purpose of this discharge procedure is to verify battery will deliver the
minimum capacity (in amps) and determine its airworthiness.
NOTE:
It may be necessary to perform a deep cycle several times to
correct a severe imbalance or loss of capacity.
(1)
Discharge the battery at a rate listed in Fig 102 until the battery
reaches 20.0 V.
(2)
Record the time at the start of the discharge and the discharge current.
(3)
Monitor individual cell voltages periodically during the discharge.
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(4)
Record the time that the first cell reaches 1.0 V.
NOTE:
It is not a cause for concern if a cell goes to zero volts or
reverses polarity during the discharge. Simply short the
terminals of that cell for the remainder of the discharge.
(5)
When the battery terminal voltage reaches 1.0 volt per cell (20.0 V),
stop the discharge and record the time.
(6)
Calculate cell capacity and battery capacity:
(a)
Calculate, in hours, the elapsed time (TC) required to discharge
the first cell to 1.0 V.
(b)
Calculate, in hours, the elapsed time (TD) required to discharge
the battery to an average of 1.0 V/cell.
(c)
Calculate minimum cell capacity (CC):
CC = TC * Discharge Current
(d)
Calculate battery capacity (CD):
CD = TD * Discharge Current
(7)
Interpretation of the Second Discharge (Capacity Test) Results
(a)
Regardless of the results obtained in the first discharge, the
battery is considered airworthy if both:
1
CC was equal or greater than 100% of the Rated Capacity
of the battery.
2
The end of charge voltage of all cells was between 1.55
and 1.82 V.
Therefore, continue with procedures necessary prior to
re-installation onto the aircraft.
(b)
Either of the following two results are indications that the battery
requires Special Testing, or refer to Fault Isolation:
1
CC was less than 100% of the Rated Capacity of the battery.
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2
G.
The end of charge voltage of any cell was less than 1.55 volts or
greater than 1.82 volts.
Cell-to-Case Insulation Test
A breakdown in electrical insulation between the cells and the battery case
will result in a “leakage” current, which over a period of time can discharge the
battery. The most common cause for the loss of insulation is the leakage of
electrolyte from the cells that can act as a conductor between the cell plates
and the battery container. Because the leakage current can affect battery
performance, it is necessary that it be kept to a minimum. The cell-to-case
insulation test should be carried out using one of the following methods:
H.
(1)
On a completely assembled battery, use a megohmmeter to measure
the insulation resistance between the positive terminals of each cell
and the outer metal case. On a battery from service, the value should
be at least 250 KΩ under 250 Vdc. Failure to meet this value indicates
a need for disassembly and cleaning (DISASSEMBLY/CLEANING).
On a new battery, or an in-service battery following disassembly and
cleaning, the value must be at least 10 MΩ under 250 Vdc. Any cell
with less than 10 MΩ resistance should be considered defective and
marked for replacement.
(2)
On a completely assembled battery, use an analog multifunction meter
capable of measurement in the 250 mA range. Adjust the meter and
input leads for measurement of 250 mA. Connect the negative lead to
the battery container. Touch the positive lead to the positive terminal
of each cell, then to the positive terminal of the battery. If there is any
deflection in the needle from zero, the insulation is inadequate and the
battery should be disassembled and cleaned. Following a thorough
cleaning, if there is still a leakage current (indicated by a deflection in
the needle from zero), the leakage should be traced to the failed cells,
and those cells marked for replacement.
Polarization Test
(1)
Charge the battery at 5.3 A for 1.5 hour.
(2)
Leave the battery in open circuit condition for 1 hour.
(3)
Measure the open voltage of each cell.
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I.
(a)
If the cell open voltage is 0 V or reversed polarity, carry out a
special test and refer to fault isolation.
(b)
If each cell’s voltage is above 0 V, charge the battery.
Special Testing
These procedures are normally used to diagnose a potential problem with one
or more cells in a battery. The test is designed to stress the battery so that
any faults may be uncovered. It is very important that continual monitoring be
performed on the cells during this test.
NOTE:
If three cells are replaced during a service cycle, or five cells are
replaced over the life of the battery, it is recommended that all
the cells in the battery be replaced.
NOTE:
It is recommended that if a battery requires Special Testing
more than three times in one service cycle that the battery be
replaced.
NOTE:
For a battery from long term storage, several complete
charge/discharge cycles may be required to restore
performance.
(1)
Fully charge the battery per Fig 104.
(2)
Continue to charge the battery at 0.1C1A (5.3 Amps) for an additional 5
hours.
(3)
Monitor individual cell voltages each 15-30 minutes during additional
overcharge and record voltage readings.
(4)
Note any cells that express a continual drop in voltage during
overcharge and mark those cells for replacement.
NOTE:
(5)
A continual drop in voltage during overcharge indicates a
failure of the gas barrier that is neither recoverable nor
repairable. A cell with a defective gas barrier must be
replaced.
Replace marked cells (if required) (DISASSEMBLY, ASSEMBLY).
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J.
Electrolyte Level Adjustment
Electrolyte level adjustment is to be performed during the last 15 minutes of
the charge cycle.
WARNING: USE CARE NOT TO TILT CELLS WHILE VENT VALVES ARE
LOOSENED OR REMOVED; CONTACT OF ELECTROLYTE WITH SKIN
CAN CAUSE SEVERE BURNS.
NOTE:
Battery must be fully charged before adjusting electrolyte level.
(1)
Remove the vent valves with vent valve wrench (P/N 093365-000).
(2)
Immerse the vent valves and their o-rings in distilled or deionized water
and let them soak to dissolve any salts.
(3)
Cover the cells with a clean damp cloth to prevent entry of foreign
matter.
(4)
Check the liquid level in the cell:
(a)
Insert the syringe (P/N 020916-001) into the cell opening until
the shoulder of the nozzle rests on the valve seat (Fig. 105).
(b)
Withdraw the plunger and check for any liquid in the syringe.
1
If the liquid level is too low, the syringe will remain empty,
indicating that the end of the syringe nozzle did not reach
the liquid in the cell.
2
Any excess liquid in the cell will be drawn into the syringe
until the electrolyte is level with the end of the nozzle.
This is the correct level for the electrolyte.
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(5)
Position of Syringe in Cell Vent Seat
Figure 105
Replenish low electrolyte:
CAUTION:
USE ONLY DISTILLED OR DEMINERALIZED WATER.
USE OF ANYTHING OTHER THAN DISTILLED OR
DEMINERALIZED WATER WILL RESULT IN
PERMANENT CELL DAMAGE.
CAUTION:
DO NOT INTENTIONALLY OVERFILL THE CELLS.
THE AMOUNT OF WATER REMOVED FROM EACH
CELL DURING THE ELECTROLYTE ADJUSTMENT
PROCESS SHOULD BE KEPT TO A MINIMUM.
Note:
The quantity (in cm3) of distilled water required to fill the
cell to the correct level will serve as an approximate guide
to the amount required for the remaining cells. The water
in each cell, however, must be adjusted individually to the
correct level. If the quantity of water added per cell is
above 70 cm3 (max consumable level is 78 cm3), check
the charging system. If the charger is functioning
properly, shorten the period between servicing.
(a)
Draw 5 cm3 of the distilled water into the syringe and inject it into
the cell.
(b)
With the syringe nozzle resting on the valve seat, slowly
withdraw the plunger in the syringe.
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K.
(c)
If the syringe remains empty, repeat steps (a) and (b), counting
the number of 5 cm3 injections required to achieve the correct
level.
(d)
At the point in step (b) when some excess liquid is drawn into
the syringe, the correct level for that cell has been reached.
Expel the excess liquid into a separate container for later
disposal.
Temperature Sensor Harness Assembly Test
Disassembly of a portion of the battery is required to test the Temperature
Sensor Harness Assembly (refer to Disassembly). Check the function of the
Temperature Sensor Harness Assembly as follows:
WARNING: TECHNICIANS PERFORMING THIS OPERATION WILL BE
EXPOSED TO TEMPERATURES IN EXCESS OF 70°C/160°F.
PROTECTIVE EQUIPMENT, SUCH AS GLOVES, MUST BE
USED DURING THIS PROCEDURE.
(1)
Insert the temperature sensors (T1 and T2) into a plastic bag with a
temperature measuring device in close proximity to the sensors.
Immerse the bag with the sensors in a beaker of water.
(2)
Using a multi-meter, check the continuity between pins A and B, and C
and D of the temperature sensor harness connector. The contacts
associated with pins A and B, and C and D are normally OPEN
(resistance > 1MΩ) below 123°F (50.6°C).
(3)
Raise the temperature of the water slowly and stabilize the
temperature of the sensors at 146°F ± 4°F (63.3°C ±2.2°C). Check the
continuity between pins A and B, and C and D of the temperature
sensor harness connector. The contact should be CLOSED
(resistance < 1MΩ).
(4)
Allow the temperature of the water to slowly drop until the temperature
of the sensors is 127°F ± 4°F (52.7°C ± 2.2°C). At this temperature the
contacts should again be OPEN. Check continuity at the temperature
sensor harness connector between pins A and B, and C and D for
resistance > 1MΩ.
Failure of any of the above continuity checks at the specified temperatures
indicates a defective temperature sensor. Replace the unit with a factory new
unit.
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L.
Vent Valve Pressure Test
Check the operation of the vent valve assemblies as follows:
(1)
Prepare a fixture from PVC pipe and fittings with an end adapter
configured on the inside to match the vent valve lugs. The adapter can
be made from PVC pipe and fittings per Fig 106.
(2)
Affix the vent valve with its O-ring into the adapter end of the pressure
test fixture.
(3)
Attach the fixture to a compressed air line through an adjustable
pressure-reducing valve limited to 20 psi (1.4 bar).
(4)
Immerse the valve and end of fixture in water, and slowly raise the
pressure. Make sure the valve opens between 2 psi and 10 psi (0.14
to 0.7 bar).
(5)
Reuse only those vent valves that open in the 2 psi to 10 psi (0.14 to
0.7 bar) range. Discard valves that are not gas tight at low pressure.
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Vent Valve Testing Apparatus (Typical Setup)
Figure 106
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4.
Fault Isolation
Fault isolation information is presented in Figure 107 as a guide in locating a cause
of malfunction and isolating the cause to a specific component.
FAULT
Zero volt with battery set to
"charge"
Zero volt with battery set to
"discharge”
POSSIBLE CAUSES
REMEDIES
Defective electrical
connector (not making
contact)
Check electrical contacts, links
and tightness of nuts (CHECK)
Link loose or broken
Replace if necessary; torque all
upper terminal nuts (Page 801)
Battery fully discharged
Recharge battery (TESTING
AND FAULT ISOLATION)
Battery circuit open or
defective contacts
Check insulation (TESTING
AND FAULT ISOLATION)
Check contacts, links and
tightness of terminal nuts
Cell(s) completely dry
Adjust electrolyte level
(TESTING AND FAULT
ISOLATION)
Fault Isolation (Sheet 1 of 5)
Figure 107
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FAULT
Leakage of electrolyte
POSSIBLE CAUSES
Incorrect adjustment of
electrolyte level
REMEDIES
Disassemble and clean the
battery (DISASSEMBLY,
CLEANING and TESTING AND
FAULT ISOLATION)
Check electrolyte level
(TESTING AND FAULT
ISOLATION)
Cell polarity reversed
Disassemble and clean the
during high rate discharge battery (DISASSEMBLY,
(e.g. during starting)
CLEANING)
Check electrolyte level
(TESTING AND FAULT
ISOLATION)
Overcharge at high
Check the on-board charging
temperatures or
circuit and if necessary adjust
excessive charge current
Disassemble and clean battery
(DISASSEMBLY, CLEANING)
Check electrolyte level
(TESTING AND FAULT
ISOLATION)
Traces of electrolyte in
battery box
Damaged cell case
Check sealing of cells (CHECK)
Leakage of electrolyte
Disassemble and clean the
battery (DISASSEMBLY,
CLEANING)
Check electrolyte level
(TESTING AND FAULT
ISOLATION)
Fault Isolation (Sheet 2 of 5)
Figure 107
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FAULT
Excessive water
consumption in all battery
cells
POSSIBLE CAUSES
REMEDIES
Heavy overcharge or
overcharge at high
temperatures
Check the on-board charging
circuit and adjust if necessary
Leaking cell(s)
Check sealing of cell(s)
(CHECK)
One or several cells whose
water consumption differs
significantly from that of other
cells in the battery:
more than 30% above
average
Disassemble and clean the
battery (DISASSEMBLY,
CLEANING)
Check electrolyte level
(TESTING AND FAULT
ISOLATION)
25% or less of the
average value
Corrosion on links
Indications of link
overheating (discoloration)
Cell(s) with damaged
separator(s)
Perform special testing
(TESTING AND FAULT
ISOLATION). If necessary,
replace with new Saft cell
(DISASSEMBLY, ASSEMBLY )
Operation in acid
atmosphere
Make sure that battery test
bench and storage areas are
free from materials which may
produce acid fumes
Mechanical damage to
nickel plating
Replace damaged links
(DISASSEMBLY, ASSEMBLY)
Loose terminal nuts
Check torque - replace
hardware with factory new
Fault Isolation (Sheet 3 of 5)
Figure 107
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FAULT
Cell with abnormally high
voltage at start of charge
POSSIBLE CAUSES
Cell dry or insufficient
electrolyte level
REMEDIES
As soon as the fault is observed
add 10 cm3 of distilled water to
the cell. Do not adjust precisely
until the end of charge.
NOTE: A cell charging with
insufficient electrolyte may also
show considerable temperature
rise
Main charge cut-off voltage
reached before minimum
time or not reached at the
maximum time
Battery not fully
discharged or strongly
unbalanced
Cell with abnormally low
voltage at end of charge
(<1.55V)
Exposure to high
Replace cell (DISASSEMBLY,
temperatures, high charge ASSEMBLY)
rates or separator
damage
Low capacity cell (reversed Normal wear after long
polarity, or a normal polarity service
voltage of less than 1V at the
end of a 1 hour discharge at
1C1A)
Exceptionally heavy use
(frequent self-starting;
operation at high
temperatures, with low
electrolyte level, etc.)
Perform a regular check
(CHECK)
Perform Regular Check
(CHECK)
Replace with new Saft cell
(DISASSEMBLY, ASSEMBLY)
Perform Regular Check
(CHECK)
Replace with new Saft cell
(DISASSEMBLY, ASSEMBLY)
Fault Isolation (Sheet 4 of 5)
Figure 107
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FAULT
POSSIBLE CAUSES
REMEDIES
Cell with zero voltage when
battery circuit is open
Short circuited cell
Replace with new Saft cell
(DISASSEMBLY, ASSEMBLY)
Low insulation
Leakage of electrolyte
Disassemble and clean battery
(DISASSEMBLY, CLEANING)
Check electrolyte level
(TESTING AND FAULT
ISOLATION)
Fault Isolation (Sheet 5 of 5)
Figure 107
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DISASSEMBLY
1.
General
This section covers detailed instruction needed to disassemble the Saft battery for
maintenance and/or repair. Disassemble only to the extent necessary to effect
repair and/or replacement.
NOTE:
2.
All ( ) part identification numbers herein are IPL Fig. 1 item numbers.
Detailed Instructions
WARNING: BATTERY CELLS DELIVER VERY HIGH CURRENTS WHEN
SHORT-CIRCUITED. EXERCISE CAUTION. REMOVE RINGS,
WATCHES OR OTHER JEWELRY.
WARNING: BATTERY MUST BE COMPLETELY DISCHARGED BEFORE CELLS
CAN BE REMOVED OR ELECTRIC SHOCK MAY OCCUR.
WARNING: DO NOT TILT BATTERY WHILE VENT VALVES ARE LOOSENED.
CONTACT OF ELECTROLYTE WITH SKIN CAN CAUSE SEVERE
BURNS.
A.
Completely discharge the battery per instructions in TESTING AND FAULT
ISOLATION.
B.
Remove cover and pad (2) by opening latches and lifting from case (1).
C.
Remove upper nuts (10a) and washers (11) from terminals of cells (3) and
connector-receptacle (14).
D.
Remove links (4 through 9) from terminals of cells (24) and connectorreceptacle (14), being careful not to damage the nickel plating.
E.
Remove Temperature Sensor Harness Assembly thermoswitches (23a and
23b) from the links by removing the attaching nut from the underside of the
link.
NOTE:
Removal of thermoswitches (23a and 23b) from the links is not
necessary unless the links are to be soaked for cleaning.
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F.
Remove the connector-receptacle (14) from the battery case (1) by removing
screws (12).
G.
Remove connector-receptacle gasket (13) from the battery case (1).
H.
Using the vent valve wrench (P/N 093365-000), loosen the vent valves (29) of
all cells to relieve any pressure; then re-tighten vent valves (use only finger
pressure on wrench when installing).
I.
Using cell puller (P/N 017557-000), remove cells (24) from the case (1) by
tightening the cell puller on cell terminal and removing cell with a steady
straight upward pull.
J.
Disassembly of the cell (24) is restricted to the removal of all hardware (10a &
10b, 11, 25 through 30).
K.
Remove the jam nut (23c) and temperature sensor harness assembly (23).
L.
Remove all liners (15-21) from the battery case (1).
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CLEANING
1.
General
CAUTION:
DO NOT USE PETROLEUM SPIRITS, TRICHLOROETHYLENE OR
ANY OTHER SOLVENTS CONTAINING CHLORIDE FOR CLEANING
THE BATTERY. USE OF THESE SOLVENTS MAY DEGRADE THE
INTEGRITY OF METAL PARTS.
NOTE:
All ( ) part identification numbers herein are IPL Fig. 1 item numbers.
A.
The following items are required to perform the cleaning procedures
(equivalent substitutes can be used):
Stiff bristle brush (non-metallic)
Small paintbrush (non-metallic)
Dry compressed air source, less than 20 psi (1.4 bar)
Safety goggles
Lubricant (non-acid petroleum jelly)
Soft, clean cloth (two required)
Isopropyl alcohol (or non petroleum-based) degreasing agent
Running water
Soap
Distilled or deionized water
2.
Light Cleaning (Assembled Battery)
A.
Discharge the battery (TESTING AND FAULT ISOLATION).
B.
Remove the battery cover and pad (2).
WARNING: USE CARE NOT TO TILT BATTERY WHILE VENT VALVES
ARE LOOSENED; CONTACT OF ELECTROLYTE WITH SKIN
CAN CAUSE SEVERE BURNS.
CAUTION:
C.
VENT VALVES MUST BE CLOSED TO PREVENT DIRT AND
FOREIGN MATTER FROM ENTERING CELLS DURING
CLEANING. VENT VALVES SHOULD BE CLOSED AT ALL
TIMES (TO AVOID EXPOSURE TO CO2), EXCEPT AS
DIRECTED OTHERWISE HEREIN. OVEREXPOSURE TO CO2
WILL AFFECT BATTERY PERFORMANCE OVER TIME.
Using vent valve wrench (P/N 093365-000), ensure that the vent valve (29) of
each cell (24) is closed and secure. Do not over-tighten.
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CAUTION: DO NOT USE A WIRE BRUSH TO CLEAN CELL TOPS.
CELLS MAY BE DAMAGED.
D.
Remove white deposits (potassium carbonate) from top of all cells (24) using
a stiff bristle non-metallic brush.
WARNING: TO PREVENT INJURY WHEN USING COMPRESSED AIR,
DIRECT STREAM AWAY FROM BODY. USE SAFETY
GOGGLES TO PREVENT INJURY TO EYES FROM FINE
DUST PARTICLES.
3.
E.
Disperse residual dust and particles from the battery with blasts of clean, dry,
compressed air not over 20 psi (1.4 bar).
F.
Coat cell nuts (10a & 10b) and all links (4 through 9) with a light film of nonacid petroleum jelly using a small paintbrush.
G.
Clean the exterior surfaces of the battery cover (2) and battery case (1) using
a soft, clean cloth moistened with water. Dry with compressed air or a dry,
clean cloth.
Thorough Cleaning
A.
Discharge the battery (TESTING AND FAULT ISOLATION).
B.
Disassemble the battery (DISASSEMBLY).
C.
Remove any greasy residue from connector-receptacle (14) with isopropyl
alcohol.
D.
After ensuring that the vent valves (29) are closed, wash each cell (24) in
running water. Do not allow any water to enter the cell. Dry with compressed
air or a dry, clean cloth.
E.
Wash the battery case (1), cover and pad (2), liners (22), connectorreceptacle gasket (13), and cell hardware (10a & 10b, 11, 25 through 30) in
warm, soapy water to remove dirt and salt deposits. A plastic scraper or a
stiff bristle brush (non-metallic) may be used to aid in the removal of heavy
deposits. Rinse away all soap, and dry with compressed air or a dry, clean
cloth.
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CAUTION:
THE LENGTH OF TIME VENT VALVES ARE REMOVED
FROM THE CELLS SHOULD BE KEPT TO A MINIMUM.
OVEREXPOSURE OF THE ELECTROLYTE TO THE
ATMOSPHERE WILL AFFECT BATTERY PERFORMANCE
DUE TO CO2 CONTAMINATION.
F.
Remove the vent valves (29) from the cells (24) using vent valve wrench, and
submerge them and their O-rings (30) in a clean container of distilled or
deionized water. This treatment will dissolve any salt deposits that may have
accumulated in the vents of the valves or around the O-ring seat. Cover the
cells (24) with a damp, clean cloth or take other precautions to prevent any
foreign particles from falling into the cells while the valves are removed.
G.
Test the vent valves (29) to ensure they operate within the correct pressure
range.
H.
Install vent valves (29) with vent wrench (P/N 093365-000).
I.
Assemble battery (ASSEMBLY).
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CHECK
1.
Initial Commissioning
A.
Before the initial charge, thoroughly inspect the battery assembly to insure no
damage has occurred during shipping or storage:
NOTE:
All ( ) part identification numbers herein are IPL Fig. 1 item
numbers.
(1)
Inspect the battery case (1) and cover (2) for dents, distortion, or other
damage. Minor dents may be straightened with a small rubber mallet
after disassembly.
(2)
Remove the battery cover and pad (2).
(3)
Visually verify the connector-receptacle (14) is installed and
undamaged.
(4)
Visually verify all cells (24) are positioned for proper polarity.
(5)
Visually verify all cells (24) are equipped with a vent valve (29).
(6)
Torque all upper nuts (10a) per Fig. 801.
(7)
Visually verify the temperature sensor harness assembly (23) is
installed and undamaged.
(8)
Charge the battery using one of the methods listed in Fig 104.
(9)
Level electrolyte using instructions found in TESTING AND FAULT
ISOLATION.
(10)
Perform cell-to-case insulation test per TESTING AND FAULT
ISOLATION.
(11)
Torque all upper nuts (10a) per Fig 801.
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2.
Assembled Battery
The following procedures are for an assembled battery with battery cover (2)
removed.
A.
Visually inspect battery for evidence of damage or electrolyte leakage. If
damage to any part is visible, refer to REPAIR and/or TESTING AND FAULT
ISOLATION for applicable procedures.
B.
Check the cell-to-case insulation (TESTING AND FAULT ISOLATION).
NOTE:
3.
A breakdown in electrical insulation between the cells and the
battery case will result in “leakage” current, which over time will
discharge the battery.
C.
Check the torque on each upper nut (10a) per Fig. 801.
D.
Check all ventilation openings to make sure that they are clean and clear.
Disassembled Battery
A.
Visually check each cell carefully for evidence of electrolyte leakage, cracks,
corrosion, burns, holes, or cross-threaded terminals. Excessive salt around a
terminal post indicates leakage.
B.
Visually check each cell vent valve (29) for defective O-rings, cracks, or other
physical damage. Replace defective O-rings (30). Vent valves that visually
appear damaged should be tested in accordance with the procedures in
TESTING AND FAULT ISOLATION and replace with factory new if
necessary.
C.
Inspect links (4 through 9) for distortion, tarnish, loss of nickel plating,
corrosion or burns. Tarnish can be polished off with a fine wire brush.
Replace any defective intercell links.
D.
Liners (22) should be clean and free of cracks or holes. Replace any that are
defective.
CAUTION:
A DEFECTIVE CONNECTOR RECEPTACLE CAN CAUSE
DANGEROUS OVERHEATING WHICH MAY CAUSE DAMAGE
TO THE BATTERY.
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E.
Check the connector-receptacle (14) for evidence of arcing, corrosion, cracks
or cross-threaded terminals. Using the Cell-to-Case Insulation Test in
TESTING AND FAULT ISOLATION, check the insulation between the positive
pin and the connector shell, and the negative pin and the connector shell.
Discard any receptacle that is found to have any of the above noted damage
or fails the insulation test.
NOTE:
F.
A defective connector-receptacle can cause battery discharge,
as well as low voltage in service.
Visually check the temperature sensor harness assembly (23) as follows:
(1)
Inspect electrical connector for bent or loose pins, corrosion, cracks,
faulty wire connections and evidence of arcing. Any evidence of the
above conditions, however minor, is cause for replacement.
(2)
Inspect thermoswitches for damaged, loose or broken wire
connections, cracks, dents, or other physical defects. Any evidence of
the above conditions, however minor, is cause for replacement.
(3)
Visually check all wiring for damage to insulation, cracked or broken
wire and other physical defects. Any evidence of the above conditions,
however minor, is cause for replacement.
NOTE:
4.
Temperature sensor harness assembly (23) is a nonrepairable item, and should be discarded if defective and
replaced with factory new.
G.
Check all hardware items for damage.
H.
Check battery cover (2) and battery case (1) for damage.
Scheduled Maintenance
Figures 501, 502 and 503 are guidelines that may be used in the performance of
specific maintenance cycles. Consult the airframe manufacturer for specific
maintenance intervals or special procedures to be followed.
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Periodic Check
Cleaning
Dust Only
Yes
Check Torque
on all nuts
Light Cleaning
No
No
Electrolyte Traces
Cell to Case
Insulation Test
> 2 Megohms
Yes
No
General Overhaul
Voltage > 21 V
No cell with reversed polarity
Yes
Polarization Test
Initial Discharge
Charge
All cells above 1.55 V
Fault Isolation
Special Test
Complete charge
5 hr additional overcharge
All cells > 1.55 V
Adjust electrolyte at end of charge
No
ADJUST ELECTROLYTE
at end of charge
< 25% difference in
electrolyte levels
Yes
Vent Valve Cleaning
General Overhaul
Check Torque
on all nuts
Battery Accepted
Maintenance Diagram
Periodic Check
Figure 501
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A.
Periodic Check: At specific watering intervals according to aircraft use, or
every 6 months, perform the following using Figure 501 as a guide:
NOTE:
Periodic and Regular maintenance checks may be combined if
operating hours do not meet intervals listed.
(1)
Remove battery assembly from aircraft.
(2)
Perform a light cleaning (CLEANING). If excessive electrolyte deposits
or salts are present, perform a thorough cleaning (CLEANING).
(3)
Discharge the battery to 1 volt/cell (TESTING AND FAULT
ISOLATION).
(4)
Recharge the battery (TESTING AND FAULT ISOLATION).
(5)
Adjust electrolyte level (TESTING AND FAULT ISOLATION).
(6)
Clean vent valves (CLEANING).
(7)
Check upper nut torque per Fig 801.
(8)
Perform cell-to-case insulation check (TESTING AND FAULT
ISOLATION).
(9)
Return battery to service.
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Regular Check
Cleaning
Dust Only
Yes
Check Torque
on all nuts
Light Cleaning
No
Voltage > 21 V
No cell with reversed polarity
No
Electrolyte Traces
Yes
Polarization Test
General Overhaul
Initial Discharge
No
Cell to Case
Insulation Test
> 2 Megohms
Yes
Residual Discharge
1 Ohm Resistor
Overnight on all cells
Charge
All cells above 1.55 V
No
Fault Isolation
ADJUST ELECTROLYTE
at end of charge
< 25% difference in
electrolyte levels
Yes
Special Test
Complete charge
5 hr additional overcharge
All cells > 1.55 V
Adjust electrolyte at end of charge
No
Capacity Test
(Second Discharge)
Yes
Vent Valve Cleaning
General Overhaul
Check Torque
on all nuts
No
Charge
All cells above 1.55 V
ADJUST ELECTROLYTE
at end of charge
Yes
Battery Accepted
Maintenance Diagram
Regular Check
Figure 502
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B.
Regular Check: At least once every 12 months, perform the following: (refer to
Fig. 502)
NOTE:
These periods are given as an indication; modify in accordance
with operational experience.
NOTE:
Periodic and Regular maintenance checks may be combined if
operating hours do not meet intervals listed.
(1)
Remove battery assembly from aircraft.
(2)
Perform a light cleaning (CLEANING). If electrolyte deposits or salts
are present, perform a general overhaul.
(3)
Perform a visual inspection.
(4)
Discharge the battery to 0 volts (TESTING AND FAULT ISOLATION).
(5)
Test temperature sensor harness assembly (TESTING AND FAULT
ISOLATION).
(6)
Perform cell-to-case insulation check (TESTING AND FAULT
ISOLATION).
(7)
Recharge the battery (TESTING AND FAULT ISOLATION).
(8)
Adjust electrolyte level (TESTING AND FAULT ISOLATION).
(9)
Perform capacity test (TESTING AND FAULT ISOLATION).
(10)
Clean and test vent valves (CLEANING, TESTING AND FAULT
ISOLATION).
(11)
Check upper nut torque per Fig 801.
(12)
Recharge the battery (TESTING AND FAULT ISOLATION).
(13)
Return battery to service.
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General Overhaul
Check Torque
on all nuts
Voltage > 21 V
No cell with reversed polarity
Scheduled
On Board Fault
Check Torque
on all nuts
Initial Discharge
Polarization Test
Residual Discharge
1 Ohm Resistor
Overnight on all cells
Disassembly
and Thorough Cleaning
Assembly
No
Visual Inspection
Cell to Case
Insulation Test
> 2 Megohms
Yes
Charge
All cells above 1.55 V
ADJUST ELECTROLYTE
at end of charge
< 25% difference in
electrolyte levels
No
Fault Isolation
No
Yes
Capacity Test
Yes
Vent Valve Cleaning
Special Test
Complete charge
5 hr additional overcharge
All cells > 1.55 V
Adjust electrolyte at end of charge
Check Torque
on all nuts
No
Replace faulty components
and return to Charge
Charge
All cells above 1.55 V
ADJUST ELECTROLYTE
at end of charge
Battery Accepted
Yes
Maintenance Diagram
General Overhaul
Figure 503
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C.
General Overhaul: At 24 months perform the following: (refer to Fig 503)
(1)
Remove battery assembly from aircraft.
(2)
Inspect the battery case (1) and cover (2) for dents, distortion, or other
damage. Straighten with a small rubber mallet if necessary.
(3)
Remove the battery cover and pad (2).
(4)
Verify all cells (24) are positioned for proper polarity.
(5)
Verify all cells (24) are equipped with a vent valve (29).
(6)
Discharge the battery to 0 volts/cell (TESTING AND FAULT
ISOLATION).
(7)
Disassemble the battery (DISASSEMBLY).
(8)
Thoroughly clean and inspect the battery (CLEANING and CHECK).
(9)
Test temperature sensor harness assembly (TESTING AND FAULT
ISOLATION).
(10)
Assemble the battery (ASSEMBLY).
(11)
Perform Cell-to-Case Insulation Test (TESTING AND FAULT
ISOLATION).
(12)
Charge the battery (TESTING AND FAULT ISOLATION).
(13)
Level electrolyte (TESTING AND FAULT ISOLATION).
(14)
Perform a Capacity Test (TESTING AND FAULT ISOLATION).
(15)
Clean and test all vent valves (TESTING AND FAULT ISOLATION).
(16)
Recharge the battery (TESTING AND FAULT ISOLATION).
(17)
Check upper nut torque per Fig 801.
(18)
Return battery to service.
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REPAIR
1.
Temperature Sensor Harness Assembly
NOTE:
All ( ) part identification numbers herein are IPL Fig. 1 item numbers.
If any part of the temperature sensor harness assembly (23) is damaged, the entire
assembly must be replaced with factory new.
2.
Cell Assembly
NOTE:
If three cells are replaced during a service cycle, or five cells are
replaced over the life of the battery, it is Saft’s recommendation that
the battery be replaced.
A.
Repair of cell (24) is limited to replacement of defective hardware (10a & 10b,
11, 25 through 27) the vent valve (29) and the lower terminal O-ring (28).
Defects to the cell itself require cell replacement with factory new.
B.
When inspection reveals electrolyte leakage from the cell at the vent hole
opening, replace the defective O-ring (30) as follows:
(1)
Using the vent-valve wrench (P/N 093365-000), loosen and remove the
vent valve (29) from the cell (24)
(2)
Cover the cell with a damp, clean cloth to prevent any foreign particles
from falling into the cell.
(3)
Remove the defective O-ring (3) from the vent valve (29 and install a
new O-ring (30) onto the vent valve (29).
(4)
Remove the cloth from the cell, and insert the vent valve (29) into the
cell (24). Using the vent valve wrench, tighten the vent valve securely
in place. To ensure they are tightened properly, use only finger
pressure on the wrench.
(5)
Clean cell (24) in accordance with CLEANING.
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C.
Replacement of the lower terminal O-ring is accomplished as follows:
CAUTION:
DO NOT WASH CELL, OR OTHERWISE ALLOW ANY
SUBSTANCES TO ENTER THE CELL WHILE O-RING IS
REMOVED. ELECTROLYTE CONTAMINATION MAY OCCUR.
(1)
Remove all hardware (25 through 27) from cell. Remove and
immediately replace O-ring (28).
(2)
Clean cell hardware (CLEANING) and reassemble cell.
(3)
Torque lower nut per Fig. 801.
NOTE:
3.
Cell terminal should be lightly greased with a non-acid
petroleum jelly prior to installation of nut.
Physical damage
When necessary, remove minor dents in the battery cover (2) and battery case (1)
using a small rubber mallet. Polish out minor pits or scratches using a piece of
emery cloth.
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ASSEMBLY
1.
General
This section contains assembly instructions necessary after disassembly.
NOTE:
All ( ) part identification numbers herein are IPL Fig. 1 item numbers.
Cells, Liners and Intercell Connector Links
Figure 701
2.
Assembly
A.
Make sure components are clean and dry before assembly.
B.
Torque the lower nut (10b) on each cell terminal (Fig. 801).
C.
Install the temperature sensor harness assembly (23) by:
(1)
Insert the temperature sensor harness assembly connector through the
hole provided in the case (1) from the inside.
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(2)
Install and tighten the jam nut onto the temperature sensor
harness assembly connector and lay the two sensors (23a and 23b)
with the wire harness over the side of the case for installation after the
cells are in place.
D.
E.
F.
Install the cells (24) and liners (22) into the case per Figure 701 using the
following steps:
(1)
Position the cells (24) to maintain correct polarity per Fig 701.
(2)
Insertion of the last cell (24) in each row may be assisted by pushing
down on its terminals with a block of softwood.
(3)
The cells (24) should be tight enough to require some effort (18 - 25 lbft // 12.98 - 18.04 N•m) to remove them.
Install the connector-receptacle (14) in the case (1) using the following steps:
(1)
Assemble connector-receptacle gasket (13) to the connectorreceptacle (14).
(2)
Insert terminals of the connector-receptacle (14) through the oval
mounting hole in the front of the battery case (1).
(3)
Attach the connector-receptacle (14) to the battery case (1) with sems
screws (12). Tighten the screws (12) per Fig 801.
Install the intercell connecting hardware using the following steps:
(1)
Recheck all cell polarities.
(2)
Attach the temperature sensors (23a and 23b) to the intercell
connector links (8 and 9). Torque nuts per Fig 801.
(3)
Mount all links (4 through 9) onto the cell terminals per Fig 701.
(a)
Replace any links that are bent, burnt, or have damaged nickel
plating.
(b)
Using a small brush, lightly coat cell terminals and links with
neutral, non-acid petroleum jelly.
NOTE:
Excessive use of petroleum jelly on the hardware
will contribute to current leakage in high ambient
temperature operations.
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(4)
Mount the washers (11) and upper nuts (10a).
NOTE:
(5)
5.
Threads of the terminals should be lightly greased with a
non-acid petroleum jelly prior to installation of nuts (10a).
Torque upper nuts per Fig. 801.
Storage
A.
General
The storage room should be free of acid, dust, or dampness. No corrosive
liquids or gases should be stored in the same room. Temperatures may
range from -75°F (-60°C) to +140°F (+60°C) without harming the battery. The
most desirable range for storage is between 32°F (0°C) to 86°F (30°C).
B.
Active stand-by storage
NOTE:
(1)
(2)
Nickel-cadmium batteries automatically self-discharge at varying
rates according to ambient temperature.
Saft vented-cell aircraft batteries may be stored charged, ready for
service in the normal upright, or vertical position for 90 days under the
following conditions:
(a)
Battery fully serviced and charged prior to storage.
(b)
Storage temperature of <68°F (20°C).
(c)
Atmosphere free of acid, dust and dampness.
(d)
No corrosive liquids or gases stored in the same room.
(e)
After 90 days the battery, a Periodic Check must be performed
(CHECK - see Fig 501).
As an alternative to (1), the battery may be kept at any temperature
below 95°F (35°C) and be “topped up” by charging until the battery has
reached the voltage specified in Fig 702.
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SAFT
COMPONENT MAINTENANCE MANUAL
024797-000
CAUTION: THE BATTERY MAY BE “TOPPED UP” TWO TIMES, ON THE
THIRD TIME A PERIODIC CHECK MUST BE PERFORMED.
FAILURE TO PERFORM THE PERIODIC CHECK MAY RESULT
IN LOW WATER AND PERMANENT DAMAGE TO BATTERY.
CHARGE RATE
5.3 Amps
21.5 Amps
53 Amps
C.
VOLTAGE TO TERMINATE CHARGE
30 Volts
31 Volts
31.4 Volts
Topping Up Charge Guide
Figure 702
Inactive long term storage
Saft Nickel Cadmium Aviation Batteries can be stored in the original
cardboard packaging for a period of two years, and up to 10 years in sealed
packaging under the following conditions:
D.
(1)
Ambient temperature of +68°F ±27°F (20°C ±15°C)
(2)
Humidity less than 70%
(3)
Normal upright, vertical position
(4)
Atmosphere free of dust, dirt, vibration or corrosive agents.
Preparation for use after storage (other than active standby storage)
STORAGE TIME
SERVICE PROCEDURE
Less than 3 months
Perform a Periodic Check (CHECK – Fig 501)
More than 3 months
Perform a Regular Check (CHECK – Fig 502)
Return to Service Procedures
Figure 703
E.
Packing and Transporting
The normal packing for shipment of Saft Ni-Cd batteries is with fiberboard or
injected foam packing enclosed in fiberboard or wooden outer containers. For
overseas shipments, wrapping in sealed plastic is recommended.
Precautions must be taken to keep batteries upright while in transit. All
markings and documentation should conform to current IATA regulations
(UN2795 or UN2800 as applicable) governing the shipment of vented Ni-Cd
batteries.
24-32-11
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SAFT
COMPONENT MAINTENANCE MANUAL
024797-000
FITS AND CLEARANCES
1.
Torque Table
Figure 801 is a listing of all torque values needed to assemble and service the
battery.
NOTE:
The values listed in Figure 801 are “lube torque” values. The threads
should be lightly greased with a non-acid petroleum jelly prior to
attaching nuts or screws.
Figure / Item Number
IPL Fig. 1
10a
IPL Fig. 1
10b
Not
Shown
IPL Fig. 1
070
2.
Torque Value
110-115 lb-in (12.64-13.21 N•m)
55-65 lb-in (6.32-7.47 N•m)
5 lb-in (2 N•m)
20 lb-in (2.48 N•m)
Torque Values
Figure 801
Name, Location
Nut, Terminal, Upper
Nut, Terminal, Lower
Nuts, Thermoswitch
Screw, Sems
Fits and Clearances Table
No fits and clearances required.
24-32-11
Page 801/802
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SAFT
COMPONENT MAINTENANCE MANUAL
024797-000
SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1.
Special Tools
A.
Battery Maintenance Kit
(1)
The Battery Maintenance Kit (Saft P/N 024629-000) is required for
performance of the TESTING AND FAULT ISOLATION and
DISASSEMBLY procedures.
The syringe (P/N 020916-001) is used in the electrolyte level
adjustment, and the cell puller (P/N 017556-000) is used in cell
removal. Spare hardware, vent valves, and O-rings are provided.
(2)
The following items are the contents of the Saft Battery Maintenance
Kit.
Nomenclature
Saft Part Number
Cell Puller
017556-000
Syringe Assembly
020916-001
17 mm Socket (3/8” Drive)
093314-000
Vent Valve Wrench
093365-000
Washer, Belleville
022228-000
O-Ring, Terminal
091181-002
Vent Valve
023619-000
Nut, Terminal
015995-000
Screw, SEMS
093616-000
Battery Maintenance Kit
Figure 901
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Mar 15/99
SAFT
COMPONENT MAINTENANCE MANUAL
024797-000
PART NUMBER
NOMENCLATURE
T
E
S
T
/
F
A
U
L
T
APPLICATION
D
C
C
R
I
L
H
E
S
E
E
P
A
A
C
A
S
N
K
I
S
I
R
E
N
M
G
B
L
Y
X
093365-000
Wrench, Vent Valve
X
020916-001
Syringe, 20 cm3 (1.22 in3) (Fig. 104)
X
017556-000
Cell Puller
024398-000
Ref Drawing
only
Check Fixture, Vent Valve
Constant Current Power Unit
(0-60 Amp)
X
X
X
X
X
X
A
S
S
E
M
.
/
S
T
O
R
E
X
X
X
X
Constant Current Load Bank
(0-60 Amp)
X
X
X
X
X
X
Equalizing resistors
(1 Ω, 3 W Minimum)
X
X
Megohmmeter
(0-50 MΩ, 0-250V continuous)
X
X
Precision Multimeter
(volt, Ω, mA)
X
X
X
X
Torque Wrench
(0-250 lb-in)
X
X
X
X
24-32-11
Page 902
Mar 15/99
SAFT
COMPONENT MAINTENANCE MANUAL
024797-000
ILLUSTRATED PARTS LIST
1.
Introduction
A.
Purpose
(1)
B.
This section provides illustrations and parts breakdown of the battery
that can be disassembled, repaired, and reassembled.
Explanation and Usage of Section
(1)
Assembly Order Indenture System
The Indenture System used in the parts list shows the relationship of
one part to another. For a given item, the number of indentures
depicts the relationship of the item to the associated next higher
assembly.
(2)
Effectivity Code
Reference letters (A, B, C, etc.) are assigned in the EFF CODE column
for each top assembly. The reference letter of the applicable top
assembly is also shown in the EFF CODE column for each detail part
and subassembly except that no reference letter is shown for detail
parts and subassemblies used on all top assemblies.
(3)
Quantity Per Assembly
The UNITS PER ASSY column shows the total number of units
required per assembly, per subassembly, and per sub-subassembly as
applicable. The letters REF indicate the item is listed for reference
purposes.
(4)
Parts Replacement Data
Interchangeability information will be provided in a future manual
revision if it becomes applicable.
(5)
Service Bulletin Incorporation
Service Bulletin incorporation information applicable to the parts list will
be provided in a future manual revision if it becomes applicable.
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SAFT
COMPONENT MAINTENANCE MANUAL
024797-000
(6)
Items Not Illustrated
Items not illustrated are indicated by a dash ( - ) ahead of the item
numbers in the FIG. and ITEM column.
(7)
Alpha Variant Item Numbers
(a)
(b)
(8)
Alpha variants A - Z (except I and O) are assigned to existing
item numbers when necessary to show:
1
Added items
2
Service Bulletin modifications
3
Configuration differences
4
Optional parts
5
Product improvement parts (non-service bulletin)
Alpha variant item numbers are not shown on the exploded view
when the appearance and location of the alpha variant item is
the same as the basic item.
Vendors
The vendors of all parts shown in the parts list are as follows:
Vendor Code
NAME / ADDRESS
Vendor Code
NAME / ADDRESS
V09052
Saft America Inc.
711 Industrial Boulevard
Valdosta, GA 31601
USA
F6177
Saft
156 Avenue de Metz
93230 Romainville
France
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SAFT
COMPONENT MAINTENANCE MANUAL
024797-000
Liners, Hardware, and Polarity, Exploded View
Figure 1 (Sheet 1 of 4)
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Mar 15/99
SAFT
COMPONENT MAINTENANCE MANUAL
024797-000
23a
23b
23
23c
Temperature Sensor
Figure 1 (Sheet 2 of 4)
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SAFT
COMPONENT MAINTENANCE MANUAL
024797-000
10a
11
10b
29
25(a & b)
30
26
27
28
24
Cell, Exploded View
Figure 1 (Sheet 3 of 4)
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Mar 15/99
SAFT
COMPONENT MAINTENANCE MANUAL
024797-000
2
24
3
10a
22
11
1
12
14
13
Battery, Exploded View
Figure 1 (Sheet 4 of 4)
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Page 1006
Mar 15/99
SAFT
COMPONENT MAINTENANCE MANUAL
024797-000
ILLUSTRATED PARTS LIST
FIG.
ITEM
1
REF
PART
NUMBER
NOMENCLATURE
1234567
.......
Battery, Nickel Cadmium (Type 5347CH1)
UNITS
PER
CODE ASSY
EFF
REF
1
024810-000 . Case, Marked 5347CH1
1
2
024812-000 . Cover and Pad Assembly, Marked
1
3
023707-000 . Handle, Web
2
4
015575-000 . Link
5
5
018569-000 . Link
3
6
015577-000 . Link
2
7
018567-000 . Link
9
8
024798-000 . Link
1
9
024799-000 . Link
1
10a
015579-000 . Nut, Hex (Upper)
42
10b
015579-000 . Nut, Hex (Lower)
40
11
022228-000 . Washer, Belleville
42
12
093616-000 . Screw, #8-32, SEMS
4
13
009384-000 . Gasket, Connector-Receptacle
1
14
022078-000 . Receptacle, Connector
1
15
*017357-033 . Liner
7
16
*017356-095 . Liner
3
17
*017355-094 . Liner
6
18
*024846-000 . Liner
2
19
*013357-078 . Liner
4
20
*013357-079 . Liner
1
21
*017356-026 . Liner
1
22
024875-000 . Kit, Liner (includes 15-21)
1
23
023046-000 . Temperature Sensor Harness Assembly
1
24
023456-000 . Cell, CVH530KA (Equipe)
20
25a
023388-001 . . Washer, Polarity Red
1
25b
023388-002 . . Washer, Polarity Blue
1
26
021871-000 . . Washer, Belleville
4
27
021870-000 . . Washer, Flat
2
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Page 1007
Mar 15/99
SAFT
COMPONENT MAINTENANCE MANUAL
024797-000
FIG.
ITEM
PART
NUMBER
NOMENCLATURE
1234567
.......
UNITS
PER
CODE ASSY
EFF
28
091181-002 . . O-Ring, Lower Terminal
2
29
023619-000 . . Valve, Vent
1
30
012536-002 . . . O-Ring, Vent-Valve
1
* = Only procurable in kit (#22) – not sold separately.
24-32-11
Page 1008
Mar 15/99